Signaling of sterile adapter and tool attachment for use in a robotic surgical system

ABSTRACT

Generally, a system for use in a robotic surgical system may be used to determine an attachment state between a tool driver, sterile adapter, and surgical tool of the system. The system may include sensors used to generate attachment data corresponding to the attachment state. The attachment state may be used to control operation of the tool driver and surgical tool. In some variations, one or more of the attachment states may be visually output to an operator using one or more of the tool driver, sterile adapter, and surgical tool. In some variations, the tool driver and surgical tool may include electronic communication devices configured to be in close proximity when the surgical tool is attached to the sterile adapter and tool driver.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.62/436,957, filed on Dec. 20, 2016, and to U.S. patent application Ser.No. 62/436,965, filed on Dec. 20, 2016, and to U.S. patent applicationSer. No. 62/436,974, filed on Dec. 20, 2016, and to U.S. patentapplication Ser. No. 62/436,981, filed on Dec. 20, 2016, the content ofeach of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

This invention relates generally to robotic surgical systems, includingbut not limited to sterile adapters for creating a sterile barrieraround portions of a robotic surgical system.

BACKGROUND

Minimally-invasive surgery (MIS), such as laparoscopic surgery, involvestechniques intended to reduce tissue damage during a surgical procedure.For instance, laparoscopic procedures typically involve creating anumber of small incisions in the patient (e.g., in the abdomen), andintroducing one or more tools and at least one camera through theincisions into the patient. The surgical procedures are then performedusing the introduced tools, with the visualization aid provided by thecamera. Generally, MIS provides multiple benefits, such as reducedpatient scarring, less patient pain, shorter patient recovery periods,and lower medical treatment costs associated with patient recovery.

MIS may be performed with non-robotic or robotic systems. Conventionalrobotic systems, which may include robotic arms for manipulating toolsbased on commands from an operator, may provide many benefits of MISwhile reducing demands on the surgeon. Control of such robotic systemsmay require control inputs from a user (e.g., surgeon or other operator)via one or more user interface devices that translate manipulations orcommands from the user into control of the robotic system. For example,in response to user commands, a tool driver having one or more motorsmay actuate one or more degrees of freedom of a surgical tool when thesurgical tool is positioned at the surgical site in the patient.

Similar to traditional surgical procedures, it is important to maintaina sterile environment in the surgical field during robotic MIS. However,various components (e.g., motors, encoders, sensors, etc.) of the tooldriver and other aspects of the robotic surgical system generally cannotpractically be sterilized using conventional sterilization methods suchas heat. One solution to maintain sterility is to provide a sterilebarrier between the tool driver (and other system components that mayappear in the surgical field such as robotic arms, etc.) and thesurgical tool, thereby providing a “non-sterile” side for the tooldriver and a “sterile” side for the surgical tool. However, the sterilebarrier generally should not interfere with how the tool driver actuatesthe surgical tool. Furthermore, as a tool driver may need to actuatedifferent surgical tools throughout a surgical procedure, the sterilebarrier may facilitate simple and efficient exchange or swapping ofsurgical tools on a tool driver, without compromising the sterilebarrier. Proper engagement and attachment of a surgical tool to a tooldriver may aid in forming a sterile barrier. Thus, it may be desirableto provide additional systems, devices, and method related to sterileadapters for use in robotic surgery.

SUMMARY

Described herein are systems, devices, and methods for determining oneor more attachment states between a tool driver, sterile adapter, andsurgical tool for control of a robotic surgical system to aid in properengagement of the sterile adapter to the system and formation of asterile barrier. These systems and methods may also be used tocommunicate a state of the sterile barrier and operation of the roboticsurgical system to help an operator and/or other users efficientlyunderstand the attachment and engagement states of the system. Systemsand methods as described herein may be used to guide an operator inperforming sterile adapter and surgical tool engagement, instead of, forexample, depending on the operator to manually confirm proper attachmentamong a sterile adapter, surgical tool, and tool driver.

Generally, the systems and methods described herein for use in a roboticsurgical system may use a tool driver configured to couple to a sterileadapter and a surgical tool. The tool driver may include at least onesterile adapter sensor and surgical tool sensor configured to generateat least one sensor signal corresponding to an attachment state (e.g.,presence, engagement, attachment, disengagement, detachment, absence,etc.) between one or more of the tool driver, sterile adapter, andsurgical tool. A controller may be coupled to the tool driver, and thecontroller may include a processor and a memory. In some variations, thecontroller may be configured to receive at least one sensor signal andgenerate attachment data using the sensor signal. The attachment datamay include at least one attachment state between the tool driver, thesterile adapter, and a surgical tool. The tool driver may be controlledusing the attachment data. One or more steps in forming the sterilebarrier may be automatically performed by the system based on theattachment data generated from the sensor signals. These features may,for example, improve a surgical tool switching process and reduceoperator error in forming a sterile barrier by ensuring that a properattachment sequence is followed for engaging the sterile adapter andsurgical tool to the tool driver. In some variations, the surgical toolmay be actuated by the tool driver when complete attachment among thetool driver, the sterile adapter, and the surgical tool has beendetermined, or the surgical tool may be inhibited from actuation by thetool driver when one or more system components is not sensed and/or isimproperly attached.

In some variations, a robotic surgical system may include a tool drivercomprising a first housing configured to attach to a surgical tool via asterile adapter. The first housing may comprise at least one projectionextending from a surface of the first housing and be configured to biasaway from the surface. The projection may comprise at least one firstsurgical tool sensor configured to generate a sensor signal comprisingat least one attachment state between the tool driver and the surgicaltool. At least one rotatable output drive may be supported by the firsthousing and be configured to communicate torque to an input drive of thesurgical tool through the sterile adapter.

In some variations, the first surgical tool sensor may comprise aproximity sensor comprising a magnet coupled to a first end of theprojection and a magnetic field transducer coupled to a second end ofthe projection. The projection may be disposed between a pair of therotatable output drives. The first housing may comprise a plurality ofthe projections arranged in a bilaterally symmetrical arrangement. Theprojection may comprise a compliant material. The projection maycomprise at least one of a coil spring and a leaf spring. A secondsurgical tool sensor may be disposed at a distal end of the firsthousing. In some of these variations, the second surgical tool sensormay comprise a proximity sensor comprising a magnetic field transducer.

In some variations, a surgical tool may comprise a second housingconfigured to attach to the sterile adapter. The second housing maycomprise a sterile adapter engagement feature comprising a magneticprojection. At least one input drive may be supported by the secondhousing and configured to receive the torque communicated from an outputdrive of the tool driver through the sterile adapter. An end effectormay extend from the second housing and be operatively coupled to theinput drive. In some of these variations, the magnetic projection maycomprise a first tapered surface and a second tapered surface oppositethe first tapered surface. In some of these variations, a distal end ofthe surgical tool may comprise the sterile adapter engagement feature.

In some variations, a tool driver for use in a robotic surgical systemmay comprise a housing configured to couple to a sterile adapter. Thehousing may comprise a sterile adapter engagement feature mateable witha corresponding tool driver engagement feature on the sterile adapter,and a sterile adapter sensor configured to generate a sensor signal whenthe tool driver engagement feature is mated with its correspondingsterile adapter engagement feature. At least one rotatable output drivemay be supported by the housing and configured to communicate torque toan input drive of a surgical tool through the sterile adapter.

In some variations, a distal end of the housing may comprise the sterileadapter engagement feature and the sterile adapter sensor. The sterileadapter engagement feature may comprise one or more of a recess and aprojection. The sterile adapter sensor may be configured to generate thesensor signal when the tool driver engagement feature contacts thesterile adapter sensor.

In some variations, one or more of a tool driver, sterile adapter, andsurgical tool may comprise respective housings each including an opticalwaveguide configured to visually communicate an attachment state amongthe tool driver, sterile adapter, and surgical tool to an operator.Furthermore, a tool driver may include an illumination source coupled toan optical waveguide configured to propagate light to a sterile adapterand surgical tool. Attachment of the tool driver, sterile adapter, andsurgical tool to each other may mechanically couple their correspondingoptical waveguides together such that light generated by the tool drivermay be output by the optical waveguide of the surgical tool viapropagation through the tool driver and sterile adapter. These featuresmay provide an operator an intuitive indication of the attachment stateof the surgical system to aid in efficient tool switching and sterilebarrier formation.

In some variations, a tool driver may include one or more surgical toolsensors configured to generate at least one sensor signal correspondingto an attachment state between the tool driver and a surgical tool. Forexample, a surgical tool sensor may be disposed in one or more biasingpegs or other projections in the tool driver, where the one or morebiasing pegs may be configured to contact a sterile adapter and urge atleast a portion of the peg away from the tool driver and toward asurgical tool. The surgical tool sensor may be disposed in apredetermined portion of the biasing peg and be configured to generatethe sensor signal. The sensor signal may be transmitted to a controllerfor processing and analysis (e.g., to determine the attachment statebetween the tool driver and the surgical tool). Additionally oralternatively, a surgical tool may include at least one sterile adapterengagement feature comprising a magnetic projection configured foraiding attachment of the surgical tool to the sterile adapter. Themagnetic projection may be sensed by another surgical tool sensor togenerate the sensor signal. In some variations, a tool driver mayinclude at least one sterile adapter sensor configured to generate asensor signal when one or more engagement features on each of thesterile adapter and the tool driver mate.

In some variations, a robotic surgical system may include a tool drivercomprising a first housing configured to attach to a surgical tool via asterile adapter. The first housing may comprise at least one projectionextending from a surface of the first housing and be configured to biasaway from the surface. The projection may comprise at least one firstsurgical tool sensor configured to generate a sensor signal comprisingat least one attachment state between the tool driver and the surgicaltool. At least one rotatable output drive may be supported by the firsthousing and be configured to communicate torque to an input drive of thesurgical tool through the sterile adapter.

In some variations, the first surgical tool sensor may comprise aproximity sensor comprising a magnet coupled to a first end of theprojection and a magnetic field transducer coupled to a second end ofthe projection. The projection may be disposed between a pair of therotatable output drives. The first housing may comprise a plurality ofthe projections arranged in a bilaterally symmetrical arrangement. Theprojection may comprise a compliant material. The projection maycomprise at least one of a coil spring and a leaf spring. A secondsurgical tool sensor may be disposed at a distal end of the firsthousing. In some of these variations, the second surgical tool sensormay comprise a proximity sensor comprising a magnetic field transducer.

In some variations, a surgical tool may comprise a second housingconfigured to attach to the sterile adapter. The second housing maycomprise a sterile adapter engagement feature comprising a magneticprojection. At least one input drive may be supported by the secondhousing and be configured to receive the torque communicated from anoutput drive of the tool driver through the sterile adapter. An endeffector may extend from the second housing and be operatively coupledto the input drive.

In some variations, the magnetic projection may comprise a first taperedsurface and a second tapered surface opposite the first tapered surface.In some of these variations, a distal end of the surgical tool comprisesthe sterile adapter engagement feature.

In some variations, a tool driver for use in a robotic surgical systemmay comprise a housing configured to couple to a sterile adapter. Thehousing may comprise a sterile adapter engagement feature mateable witha corresponding tool driver engagement feature on the sterile adapter,and a sterile adapter sensor configured to generate a sensor signal whenthe tool driver engagement feature is mated with its correspondingsterile adapter engagement feature. At least one rotatable output drivemay be supported by the housing and be configured to communicate torqueto an input drive of a surgical tool through the sterile adapter. Insome of these variations, a distal end of the housing may comprise thesterile adapter engagement feature and the sterile adapter sensor. Thesterile adapter engagement feature may comprise one or more of a recessand a projection. The sterile adapter sensor may be configured togenerate the sensor signal when the tool driver engagement featurecontacts the sterile adapter sensor.

In some variations, the respective housings of the tool driver andsurgical tool may define portions to support respective electroniccommunication devices that may lie in close proximity to each other whenthe surgical tool is attached to the sterile adapter and tool driver.Close proximity between the electronic communication devices may reducesignal interference, improve power efficiency, and enable wireless powertransfer between electronic devices disposed within the tool driver andsurgical tool. For example, an electronic communication device of thetool driver may be in a same plane as a rotatable output drive disk ofthe tool driver. A corresponding electronic communication device of thesurgical tool may be disposed in a projection of a surgical tool housingon a side facing the tool driver. When the tool driver, sterile adapter,and surgical tool are attached to each other, a distance between theelectronic communication devices may be reduced, if not minimized, inorder to improve one or more of signal-to-noise ratio (SNR) and powertransfer efficiency.

In some variations, a robotic surgical system may include a tool drivercomprising a first housing configured to attach to a surgical tool via asterile adapter. At least one output drive may be coupled to acorresponding rotatable output drive disk each supported by the firsthousing. The output drive may be configured to communicate torque to aninput drive of the surgical tool through the sterile adapter. A firstelectronic communication device may be configured to wirelesslycommunicate with the surgical tool and disposed substantially in a planeof the output drive disk.

In some variations, the surgical tool may comprise a second housingconfigured to couple to the sterile adapter. The second housing maycomprise a projection and a second electronic communication deviceconfigured to wirelessly communicate with the tool driver. The secondelectronic communication device may be disposed in the projection. Anend effector may extend from the second housing and be operativelycoupled to the input drive. The input drive may be supported by thesecond housing and configured to receive torque communicated from theoutput drive of the tool driver through the sterile adapter.

In some variations, the sterile adapter may comprise a frame configuredto be interposed between the tool driver and the surgical tool. A plateassembly may be coupled to the frame. The frame may comprise acommunication portion configured to support the projection of thesurgical tool substantially in a plane of the plate assembly when thesurgical tool is attached to the sterile adapter and the plate assemblyis biased toward the tool driver. At least one rotatable coupler may besupported by the plate assembly and configured to communicate torquefrom the output drive of the tool driver to the input drive of thesurgical tool.

A proximal end of the first housing may be configured to support thefirst electronic communication device. In some of these variations, aproximal end of the surgical tool may comprise the projection. In someof these variations, a proximal end of the frame may comprise thecommunication portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustrative schematic of a portion of a robotic surgicalsystem depicting a tool driver, sterile adapter, sterile barrier, andsurgical tool.

FIG. 2 is an illustrative state diagram for a robotic surgical controlsystem.

FIGS. 3A-3C are perspective views of a variation of a robotic surgicalsystem depicting one or more of a tool driver, sterile adapter, andsurgical tool. FIG. 3A is a perspective view of a tool driver, FIG. 3Bis a perspective view of a sterile adapter coupled to the tool driver,and FIG. 3C is a perspective view of a surgical tool coupled to thesterile adapter and tool driver.

FIGS. 4A-4E are illustrative views of a variation of a tool driver indifferent configurations. FIG. 4A is a plan view of the tool driver.FIGS. 4B-4C are cross-sectional side views of the tool driver depictedin FIG. 4A. FIGS. 4D-4E are detailed cross-sectional side views ofrespective FIGS. 4B-4C.

FIGS. 5A-5C are illustrative views of a variation of a tool driver andsurgical tool. FIG. 5A is a plan view of the tool driver. FIG. 5B is across-sectional side view of the tool driver depicted in FIG. 5A. FIG.5C is a detailed cross-sectional side view and a portion of a surgicaltool and the tool driver depicted in FIG. 5B.

FIGS. 6A-6B are illustrative views of some variations of a sterileadapter and surgical tool. FIG. 6A is a cross-sectional side view of onevariation of a sterile adapter and surgical tool. FIG. 6B is a detailedcross-sectional side view of another variation of a sterile adapter andsurgical tool.

FIGS. 7A-7C are illustrative views of a variation of a tool driver andsterile adapter. FIG. 7A is a plan view of the tool driver coupled to asterile adapter, FIG. 7B is a cross-sectional side view of the tooldriver and sterile adapter depicted in FIG. 7A, and FIG. 7C is adetailed cross-sectional side view of the tool driver and sterileadapter depicted in FIG. 7B.

FIG. 8 is a detailed cross-sectional side view of a variation of a tooldriver and surgical tool including respective electronic communicationdevices.

FIGS. 9A-9B are block diagram schematics of a variation of a roboticsurgical system.

DETAILED DESCRIPTION

Described here are systems, devices, and methods for controlling arobotic surgical system using a tool driver, sterile adapter, andsurgical tool. As shown generally in the schematic of FIG. 1, a roboticsurgical system (10) may comprise a tool driver (100) configured toactuate a surgical tool (120). One or more drive outputs (102) of thetool driver (100) may, for example, actuate one or more drive inputs(not shown) on a proximal portion (122) of the surgical tool (120),thereby causing movement (e.g., grasping, cutting) of an end effector(not shown) located at a distal end of a tool shaft (124). Additionally,a sterile barrier (150) may be placed between the tool driver (100) andthe surgical tool (120), forming a barrier between an interior,non-sterile side including the tool driver (100) and an exterior,sterile side including the surgical tool (120) which may, for example,be located at a sterile surgical site. The sterile barrier (150) may,for example, include a sterile drape (130) configured to cover at leastthe tool driver (100), and a sterile adapter (110) coupled to thesterile drape (130) and located between the tool driver (100) and thesurgical tool (120). The sterile adapter (110) may be configured tocommunicate or otherwise transmit an actuation force (e.g., rotarytorque, linear movement) from at least one drive output (102) of thetool driver (100) to at least one drive input of the surgical tool(120). Examples of tool drivers (100), sterile adapters (110), andsurgical tools (120) are described in more detail herein.

Generally, the systems and methods described herein may includeattaching a sterile adapter and a surgical tool to a tool driver. One ormore sensors disposed in one or more of the tool driver, sterileadapter, and surgical tool may be configured to generate sensor signalsused to monitor and advance the attachment process. For example,attachment of the sterile adapter to the tool driver may be sensed andvisually communicated to an operator through color-coded light outputfrom optical waveguides (e.g., light pipe) of one or more of the tooldriver and the sterile adapter. Furthermore, upon determination ofsterile adapter attachment, the tool driver may be actuated withoutoperator input to fully engage (e.g., attach) the sterile adapter to thetool driver in order to prepare the surgical system for surgical toolattachment. On the other hand, when the sensor detects improperattachment to the tool driver, the operator may be notified of the errorthrough color-coded light output from an optical waveguide of the tooldriver. In such situations, the tool driver may be inhibited fromoperating (e.g., to prevent damage to the system and/or operator).Disengagement and/or detachment of the surgical system may also besensed and subsequently communicated to an operator (e.g., visuallycommunicated using an optical waveguide). Using sensors to determine anattachment state between the tool driver, sterile adapter, and surgicaltool and communicating the attachment state to an operator may, forexample, aid in efficiently performing tool switching and proper sterilebarrier formation.

In some variations, an attachment state between a tool driver, sterileadapter, and surgical tool may be output by the robotic surgical systemto an operator using one or more output modalities. In some variations,one or more of the tool driver, sterile adapter, and surgical tool mayinclude a visual output device for communicating the attachment state toan operator quickly and intuitively. For example, upon attachment of thesterile adapter and/or surgical tool to the tool driver, respectiveoptical waveguides of the attached components may indicate theattachment state. Additionally or alternatively, the surgical system mayinclude other visual output devices such as a user console (e.g.,surgeon bridge) and/or display device. The operator may additionally oralternatively receive audio and haptic output from the respective audioand haptic devices.

Attachment state data may be generated using one or more sensor signals.In some variations, a tool driver may include at least one surgical toolsensor configured to generate a sensor signal corresponding to anattachment state between the tool driver and a surgical tool. The sensorsignal may be used to generate attachment data. The attachment data maybe used to control the tool driver and/or output an attachment state toan operator. In some variations, one or more biased projections (e.g.,biasing pegs) may extend from a surface of a tool driver housing. Theprojection may be biased to contact and urge a portion of a sterileadapter away from a tool driver housing and towards a surgical tool. Afirst surgical tool sensor (e.g., proximity sensor) may be disposedwithin the projection and configured to determine an amount of movementof the projection relative to the tool driver housing. An attachmentstate between the tool driver and surgical tool may be derived from thesurgical tool sensor data.

In some variations, a tool driver may include a second surgical toolsensor configured to generate another sensor signal corresponding toattachment between the surgical tool and the sterile adapter to the tooldriver. In some variations, the second surgical tool sensor may be aproximity sensor (e.g., magnetic field transducer) configured to detecta magnetic projection of a surgical tool. As other examples, the secondsurgical tool sensor may include a switch (e.g., that detect physicalcontact between the surgical tool and/or sterile adapter to the tool),an optical sensor, an inductive sensor, and/or other suitable sensor. Anattachment state between the tool driver and surgical tool may bederived from the sensor signal generated from the second surgical toolsensor. In some variations, the magnetic projection may be configured tomate with a corresponding recess in the sterile adapter. The surfaces ofthe projection may be configured to guide attachment of the surgicaltool to the sterile adapter. Thus, the projection may aid in properalignment and attachment (e.g., seating) of the surgical tool to thesterile adapter.

In some variations, a tool driver may include at least one sterileadapter sensor configured to generate a sensor signal when the sterileadapter is fully attached to the tool driver. For example, the sterileadapter sensor may generate the sensor signal when correspondingengagement features on the tool driver and the sterile adapter makecontact and mate. In other examples, the sterile adapter sensor mayadditionally or alternatively include another suitable sensor (e.g.,proximity sensor) for detecting when the sterile adapter is fullyattached to the tool driver. The sensor signal may be used to generateattachment data for controlling the tool driver. The sterile adaptersensor may be disposed on a portion of the housing of the tool driver(e.g., distal end) such that improper contact and/or partial attachmentof the sterile adapter to the tool driver generates a correspondingsensor signal.

In some variations, the tool driver and surgical tool may includeelectronic communication devices disposed in a tool driver and surgicaltool to communicate tool and system data with each other. Thecommunication devices may be configured to be in close proximity (e.g.,within a few millimeters) when the surgical tool is attached to thesterile adapter and tool driver. Close proximity between the electroniccommunication devices permits reduced signal interference and may enablewireless power transfer between the tool driver and surgical tool. Afirst electronic communication device of the tool driver may be disposedclose to a side of a tool driver housing facing the surgical tool tominimize the distance between the first electronic communication deviceand the surgical tool. Likewise, a second electronic communicationdevice of the surgical tool may be disposed close to a side of thesurgical tool housing facing the tool driver to minimize the distancebetween the second electronic communication device and the tool driver.The sterile adapter may include a communication portion configured tosupport the second electronic communication device such that thedistance between the surgical tool and tool driver is minimized when thesterile adapter is interposed between them.

I. Methods

Described herein are methods for controlling a robotic surgical systemusing the systems and devices described herein. Generally, the methodsdescribed here include using one or more sensors to generate anattachment state between a surgical tool, sterile adapter, and tooldriver. In response to the attachment state, a controller may controloperation of the tool driver and output (e.g., notify) the attachmentstate to an operator. For example, the methods described here mayinclude determining partial attachment of a sterile adapter to a tooldriver, and subsequently actuating output drives of the tool driver tofully attach the sterile adapter to the tool driver. The system maynotify the attachment state to the operator (e.g., partial attachment,full attachment, partial detachment, full detachment, improperattachment) using one or more of audio, visual and haptic output. Any ofthe devices and systems as described herein may be used to perform themethods discussed herein. For example, a system may include a tooldriver configured to attach to a surgical tool via a sterile adapter.The tool driver may comprise at least one sterile adapter sensor and/orat least one surgical tool sensor. These sensors may be configured togenerate at least one sensor signal used to generate an attachment stateof the system (e.g., the sterile adapter sensor may be configured togenerate a sensor signal corresponding to an attachment state betweenthe tool driver and the sterile adapter, and/or the surgical tool sensormay be configured to generate a sensor signal corresponding to anattachment state between the surgical tool/sterile adapter and the tooldriver). A controller comprising a processor and a memory may be coupledto the tool driver and used to control actuation of the tool driver.

Generally, the methods described herein may include receiving the sensorsignal generated by one or more sensors of the tool driver andgenerating attachment data using the sensor signal. For example, acontroller may receive and process the sensor signal to generateattachment data. The attachment data may comprise at least oneattachment state between the tool driver, the sterile adapter, and thesurgical tool. Tool driver operation and/or operator notification may bebased on the attachment data. The methods described herein may, forexample, aid proper engagement of a surgical tool and sterile adapter tothe tool driver for formation of a sterile barrier. This may have one ormore benefits, such as efficient tool switching and sterile barrierformation, as well as increased safety as the system need not rely onoperator confirmation of an attachment state. FIG. 2 is a state diagramthat describes an illustrative method of controlling a system asdescribed herein. Of course, the exemplary variation described in FIG. 2is provided for the sake of illustrative description and isnon-limiting.

In some variations, the attachment state of the system may becommunicated to the operator using one or more output methods (e.g.,described in detail with respect to FIGS. 3A-3C). For example, a statusof the system may be communicated to the operator using a set of lightpatterns emitted from respective optical waveguides (e.g., light pipe)of one or more of the tool driver, sterile adapter, and surgical tool.The light patterns described herein may, for example, comprise one ormore of flashing light, occulting light, isophase light, etc., and/orlight of any suitable light/dark pattern. For example, flashing lightmay correspond to rhythmic light in which a total duration of the lightin each period is shorter than the total duration of darkness and inwhich the flashes of light are of equal duration. Occulting light maycorrespond to rhythmic light in which the duration of light in eachperiod is longer than the total duration of darkness. Isophase light maycorrespond to light which has dark and light periods of equal length.Light pulse patterns may include one or more colors (e.g., differentcolor output per pulse), light intensities, and frequencies. Variationsof optical waveguides of the system are described in further detailherein. In some variations, one or more of visual, audible, and hapticoutput may be provided to an operator to communicate an attachment stateof the system.

As another example, the attachment state of the system may additionallyor alternatively be visually communicated to the operator using adisplay device. Variations of display devices of the system aredescribed in further detail herein and may comprise, for example, one ormore of an LED display, touch screen display, user console, virtualreality headset, and other suitable displays.

As another example, the attachment state of the system may additionallyor alternatively be audibly communicated using an audio device.Variations of audio devices of the system are described in furtherdetail herein and may comprise, for example, one or more of a speaker,user console, virtual reality headset, and other suitable audio devices.

As yet another example, the attachment state of the system mayadditionally or alternatively be haptically communicated using a hapticdevice. Variations of haptic devices of the system are described infurther detail herein and may comprise, for example, a vibrational motorin at least one of the tool driver, distal portion of the arm, inputdevice (e.g., hand-held controller), and other suitable haptic devices.

Sterile Adapter Ready State

In some variations, the control process (200) may include a sterileadapter ready state (202) in which both a sterile adapter and surgicaltool are fully detached from a tool driver. One or more surgical toolsensors (e.g., described in detail with respect to FIGS. 4D-4E and 6B)may output a sensor signal corresponding to a detachment state betweenthe tool driver and a surgical tool. A sterile adapter attachment sensor(e.g., described in detail with respect to FIG. 7C) may output a sensorsignal corresponding to a detachment state between the tool driver and asterile adapter. Consequently, the tool driver may be inhibited fromdriving an output drive in the sterile adapter ready state (202) basedon these sensor signals.

Referring back to FIG. 2, a tool driver may output a first light pattern(220) corresponding to the sterile adapter ready state (202). In somevariations, the tool driver may output a slow pulse of colored light(e.g., blue light) at a predetermined light intensity using a firstoptical waveguide of the tool driver (e.g., see FIG. 3A). For example,the first light pattern may comprise pulses of light having a durationof about half a second or more. Additionally or alternatively, a displaydevice may output text or an image indicating that the system is readyfor attachment of a sterile adapter to the tool driver. For example, auser console (e.g., surgeon bridge) coupled to the system may display amessage to the operator such as “Please attach the sterile adapter tothe tool driver” and/or “Ready for sterile adapter attachment.” In somevariations, the sterile adapter ready state (202) may correspond to afirst audio pattern and first haptic pattern that inhibits audio andhaptic output. In other variations, an audio device may output a soundeffect (e.g., bing, ping, beep, etc.) and/or verbal message at apredetermined time interval to remind an operator to attach a sterileadapter to the tool driver.

Sterile Adapter Engagement State

An operator may at least partially attach a sterile adapter to the tooldriver. In response, a controller may determine that the systemtransitions from a sterile adapter ready state (202) to a sterileadapter engagement state (204) corresponding to partial attachment ofthe sterile adapter to the tool driver. In some variations, partialattachment of the sterile adapter to the tool driver may mean at least aportion of the sterile adapter may be attached to the tool driver, butat least another portion of the sterile adapter may be detached ordisengaged from the tool driver.

For example, in a variation in which a tool driver includes at least onerotatable output drive (e.g., rotary axis drive), a sterile adapter mayinclude a frame and at least one rotatable coupler configured totransmit torque from the rotatable output drive to a surgical tool.Partial attachment of the sterile adapter to the tool driver may meanthe frame may be attached to the tool driver, but at least one rotatablecoupler of the sterile adapter may not be operatively coupled withcorresponding output drives of the tool driver (and thereby fail totransmit torque). For example, FIGS. 7A-7B illustrate attachment of anexemplary sterile adapter to a tool driver. In some variations, anoperator may attach a proximal end of the sterile adapter to the tooldriver before attachment of a distal end of the sterile adapter. Thesystem may then determine the transition from the ready state (202) tothe engagement state (204) when a sensor signal corresponding to partialattachment of the sterile adapter to the tool driver (222) is generatedby a sterile adaptor sensor. One or more surgical tool sensors (e.g.,see FIGS. 4D, 4E, and 5C) may generate a sensor signal corresponding todetachment between the surgical tool and the tool driver. Thiscombination of sensor signals may correspond to partial attachment wherethe sterile adapter is partially attached to the tool driver, but notready for surgical tool loading (206).

In response to the partial attachment of the sterile adapter to the tooldriver (222), a controller of the system may actuate one or morerotatable output drives of the tool driver to physically engage therotatable output drives of the tool driver to corresponding rotatablecouplers of the sterile adapter (224). For example, the sterile adaptermay comprise a frame and a plate assembly coupled to the frame. Theplate assembly may be configured to have a range of motion perpendicularto a plane of the frame. The plate assembly may comprise at least onerotatable coupler supported by the plate assembly. The rotatable couplermay be configured to communicate the torque output from the output driveof the tool driver. In systems including other variations of tooldrivers and sterile adapters, the controller of the system may actuateat least a portion of the tool driver in any suitable manner so as toengage an output drive to a corresponding portion of a sterile adapter.For example, in a system including a tool driver having at least onelinear output drive and a sterile adapter having at least onelinearly-movable coupler or other interface configured to engage thelinear output drive, the controller may actuate the linear output drive(e.g., distally and/or proximally in an axial direction) so as to engagethe linear output drive with the linearly-movable coupler.

In some variations, the tool driver may output a second light pattern inresponse to determining the partial attachment state of the sterileadapter. In some variations, the tool driver may output a fast pulse ofcolored light (e.g., blue light) at a predetermined light intensityusing an optical waveguide of the tool driver. For example, the secondlight pattern may comprise pulses of light having a duration of lessthan about half a second (e.g., about ¼ second). In some variations, asfurther described herein, attachment of the sterile adapter to the tooldriver may mechanically couple the optical waveguides (e.g., lightpipes) of the sterile adapter and tool driver together such that lightemitted by an illumination source of the tool driver may be propagatedthrough and distributed by the optical waveguide of the sterile adapter.The light output by the sterile adapter confirms to the operator thatthe sterile adapter is attached to the tool driver. This may allow anoperator to quickly identify the sterile adapter engagement state (204)by looking at multiple visual indicators (e.g., color, pulse frequency,light distribution, etc.) output by the tool driver and the sterileadapter.

Additionally or alternatively, a display device may output text or animage indicating that the sterile adapter is partially attached to thetool driver in the sterile adapter engagement state (204). For example,a user console coupled to the system may display a message to theoperator such as “Sterile adapter detected,” “Sterile adapter attachedto tool driver,” and/or “Engaging sterile adapter disks.” In somevariations, an audio device may output a second audio patterncorresponding to the sterile adapter engagement state. For example, theaudio device may output a set of fast, short bings, or other suitablesound effects at a predetermined frequency and volume for apredetermined length of time. A second haptic pattern may correspond tothe sterile adapter engagement state and inhibit haptic output. In othervariations, the audio device may output the message displayed by theuser console and/or verbally output the operational steps of the tooldriver in response to attachment of the sterile adapter (e.g., “Engagingsterile adapter disks”).

Conversely, the operator may detach the sterile adapter from the tooldriver by, for example, rotationally lifting the sterile adapter offfrom a distal end of the tool driver. The system may transition from thesterile adapter engagement state (204) to the sterile adapter readystate (202) when a sensor signal from a sterile adaptor sensor isgenerated that corresponds to detachment between the sterile adapter andthe tool driver (226). Likewise, one or more surgical tool sensors maygenerate a sensor signal corresponding to detachment between thesurgical tool and the tool driver. The tool driver may be inhibited fromactuating an output drive in the sterile adapter detachment state (226).In some variations, one or more of visual, audio, and haptic output mayalso be inhibited when detachment of the sterile adapter is sensed(226).

Surgical Tool Loading Readiness State

From the sterile adapter engagement state (204), a controller maydetermine a transition of the system into a surgical tool loadingreadiness state (206). For example, the controller may rotate therotatable output drives of the tool driver for a predetermined number ofrevolutions in one or more directions (e.g., clockwise,counter-clockwise) to fully attach the sterile adapter to the tooldriver. The tool driver and sterile adapter may be in a tool loadingreadiness state (206) when the rotatable couplers of the sterile adapterare fully physically engaged with their corresponding rotatable outputdrives of the tool driver. Upon full attachment, torque generated by theoutput drives may be communicated to the couplers of the sterileadapter. In some variations, the rotatable output drives may rotateuntil a change in torque is detected in the output drives using one ormore torque sensors and rotary encoders. A change in torque maycorrespond to added resistance from the rotatable couplers that indicatethat the rotatable couplers have physically engaged with theircorresponding output drives of the tool driver.

In some variations, one or more of the tool driver and sterile adaptermay output a third light pattern from the system to notify an operatorof the tool loading readiness state (206). In some variations, one ormore of the tool driver and sterile adapter may output solid coloredlight (e.g., blue light) at a predetermined light intensity using anoptical waveguide of the tool driver and/or sterile adapter.Additionally or alternatively, a display device may output text or animage indicating that the system is ready for attachment of a surgicaltool to the sterile adapter and tool driver. For example, a user consolecoupled to the system may display a message to the operator such as“Please attach a surgical tool to the tool driver” and/or “Ready fortool loading.” In some variations, an audio device may output a thirdaudio pattern corresponding to the tool loading readiness state (206).For example, the audio device may output one or more extended bings(having a duration longer than a short bing) at a predeterminedfrequency and volume for a predetermined length of time. A third hapticpattern may correspond to the surgical tool loading readiness state andinhibit haptic output. In other variations, the audio device may outputthe message displayed by the user console and/or verbally describe theactuation of the tool driver in response to the tool loading readinessstate (206).

In some circumstances, after attachment of the sterile adapter to thetool driver, an operator may detach the sterile adapter from the tooldriver. The system may transition from the tool loading readiness state(206) to the sterile adapter ready state (202) when a sensor signalgenerated by a sterile adaptor sensor corresponds to detachment of thesterile adapter from the tool driver (226). Likewise, one or moresurgical tool sensors may generate a sensor signal corresponding todetachment of a surgical tool from the tool driver.

Surgical Tool Engagement State

Once the sterile adapter is fully attached to the tool driver, anoperator may partially attach a surgical tool to the sterile adapter. Inresponse, a controller may determine that the system transitions fromthe surgical tool loading readiness state (206) to the surgical toolengagement state (208) corresponding to partial attachment of thesurgical tool to the sterile adapter (228). In some variations, partialattachment of the surgical tool to the sterile adapter may mean at leasta portion of the surgical tool may be attached to the sterile adapter,while another portion of the surgical tool may be detached or disengagedfrom the sterile adapter. For example, the housing of the surgical toolmay be attached to a frame of the sterile adapter to the tool driver,but input drives of the surgical tool may not be operatively coupledwith corresponding rotatable couplers of the sterile adapter. The systemmay then transition from the readiness state (206) to the toolengagement state (208) of a sensor signal corresponding to partialattachment between the surgical tool and the sterile adapter (228) isgenerated by one or more surgical tool sensors. One or more projections(e.g., biasing pegs) of the tool driver (see e.g., FIGS. 4B-4E andaccompanying description herein) may generate a sensor signalcorresponding to the projections being pushed downward toward a surfaceof the tool driver momentarily (as the operator pushes the surgical toollongitudinally over a surface of the sterile adapter). The projectionsmay then bias away from the surface of the tool driver (as the surgicaltool becomes seated within the plate assembly of the sterile adapter).For example, a surface of the sterile adapter may comprise matingfeatures (e.g., projections) that create an uneven surface and areconfigured to mate with corresponding mating features (e.g., recesses)on the sterile adapter. When an operator slides the surgical tool overthe sterile adapter, the projections may slide over the surface of theplate assembly unevenly so as to momentarily push the plate assemblydownward. When the projections mate into corresponding recesses, theplate assembly may bias back upward.

In some variations, a mating feature of a surgical tool may be used todetermine an attachment state of the surgical tool. For example, asecond surgical tool sensor (e.g., proximity sensor) disposed on adistal end of the tool driver and facing the sterile adapter maygenerate a sensor signal corresponding to the presence of the surgicaltool when a magnetic projection of the surgical tool is slid into acorresponding recess of the sterile adapter (see e.g., FIGS. 6A-6B andaccompanying description herein). For example, the output of the secondsurgical tool sensor may indicate that the surgical tool is attached toand fully seated in the sterile adapter so as to be ready for inputdrive coupling.

In some variations, a tool driver may further comprise a sterile adaptersensor configured to generate a sensor signal corresponding to anattachment state between the tool driver and the sterile adapter. Forexample, as further described herein with reference to FIGS. 7A-7C, insome variations, a distal end of the sterile adapter may be mechanicallylatched to the tool driver to engage with the sterile adapter sensor.The combination of these surgical tool and sterile adapter sensorsignals may be used by a controller to transition the system from thetool loading readiness state (206) to the tool engagement state (208).

In some variations, the tool driver and surgical tool may each compriserespective electronic communication devices such as wirelesscommunication devices configured to communicate with each other and/ortransfer power wirelessly when they are in close proximity (e.g., withina few centimeters). Attachment of the surgical tool to the sterileadapter and the tool driver may correspond to the electroniccommunication devices becoming within a predetermined range of eachother. An exemplary arrangement with such respective electroniccommunication devices is described below with reference to FIG. 8.

In response to the tool engagement state (208), a controller of thesystem may actuate one or more rotatable output drives of the tooldriver to physically engage the rotatable output drives of the tooldriver with corresponding rotatable input drives of the surgical tool.In some variations, the tool driver may output a fourth light pattern inresponse to the partial attachment state of the surgical tool. In somevariations, one or more of the tool driver, sterile adapter, andsurgical tool may output a fast pulse of colored light (e.g., greenlight) at a predetermined light intensity using one or more opticalwaveguides of the tool driver, sterile adapter, and surgical tool. Forexample, the fourth light pattern may comprise pulses of light having aduration of less than about half a second (e.g., about ¼ second). Insome variations, attaching the surgical tool to the sterile adapter maymechanically couple the waveguides of the surgical tool, sterileadapter, and the tool driver together such that light generated by thetool driver may be propagated to and distributed by the opticalwaveguides of the sterile adapter and/or surgical tool. This may allowan operator to quickly confirm the tool engagement state (208) betweenthe tool driver and the surgical tool by simply looking at which systemcomponent is emitting light.

Additionally or alternatively, a display device may output text or animage indicating that the surgical tool is partially attached to thetool driver in the tool engagement state (208). For example, a userconsole coupled to the system may display a message to the operator suchas “Surgical tool detected,” “Surgical tool attached to tool driver,”and/or “Engaging surgical tool input drives.” In some variations, anaudio device may output a fourth audio pattern corresponding to the toolengagement state (208). For example, the audio device may output a setof fast, short bings at a predetermined frequency (e.g., different fromthe frequency of the second audio pattern) and predetermined volume fora predetermined length of time. A haptic device may output a fourthhaptic pattern corresponding to the tool engagement state (208). Forexample, a haptic device of one or more of the tool driver and surgicaltool may output a small vibration. In other variations, the audio devicemay output the message displayed by the user console and/or verballydescribe the actuation of the tool driver in response to surgical toolattachment (e.g., actuation of one or more output drives). In somevariations, the electronic communication device (e.g., wirelesscommunication device) of the surgical tool in the tool engagement statemay transmit tool functionality and other data (e.g., security data,utilization data, diagnostic data, manufacturing data, etc.) to theelectronic communication device of the tool driver. In turn, theelectronic communication device of the surgical tool may receiveauthentication data and/or other data (calibration data, usage data, logdata, surgical system data, patient data, procedure data, regulatorydata, etc.) that may be stored in a memory of the surgical tool.

Surgical Tool Readiness State

A controller may control a system in the tool engagement state (208) totransition (230) into a surgical tool readiness state (210) thatcorresponds to a full attachment state between the surgical tool,sterile adapter, and tool driver. For example, a tool driver may rotatethe rotatable output drives for a predetermined number of revolutions inone or more directions (e.g., clockwise, counter-clockwise) to fullyseat the surgical tool in the sterile adapter. The surgical tool in thetool readiness state (210) may then be actuated via the tool driver tooperate the surgical tool under operator guidance. The tool driver andsurgical tool may be in a tool readiness state (210) when the rotatableinput drives of the surgical tool are fully physically engaged (e.g.,fully attached) with their corresponding rotatable output drives of thetool driver. When the surgical tool is fully attached (e.g., fullyseated), torque generated by the output drives may be communicated tothe input drives of the tool driver. In some variations, the rotatableoutput drives may rotate until a predetermined change in torque isdetected in the output drives using one or more torque sensors androtary encoders. A reduction in torque may indicate that the inputdrives of the surgical tool encountered resistance and have physicallyengaged with their corresponding output drives of the tool driver.

In some variations, one or more of the tool driver, sterile adapter, andsurgical tool may output a fifth light pattern to indicate the toolreadiness state (210). In some variations, one or more of the tooldriver, sterile adapter, and surgical tool may output solid coloredlight (e.g., green light) at a predetermined light intensity using anoptical waveguide of one or more of the tool driver, sterile adapter,and surgical tool. Additionally or alternatively, a display device maydisplay a message to the operator such as “Tool ready for use” and/or“Tool fully attached.” In some variations, an audio device may outputone or more extended bings (longer than a short bing) at a predeterminedfrequency (different from the third audio pattern) and volume for apredetermined length of time. A fifth haptic pattern may inhibit hapticoutput. In other variations, the audio device may output the messagedisplayed by the user console and/or verbally describe the actuation ofthe tool driver in response to the tool readiness state (210). In somevariations, an electronic communication device (e.g., wirelesscommunication device) of the surgical tool may transmit toolfunctionality and other data (e.g., security data, usage data, log data,diagnostic data, manufacturing data, etc.) to the electroniccommunication device of the tool driver. In turn, the electroniccommunication device of the surgical tool may receive authenticationdata and/or other data (calibration data, usage data, surgical systemdata, patient data, procedure data, regulatory data, etc.) that may bestored in a memory of the surgical tool. In some variations, the tooldriver may be configured to wirelessly transfer power from the tooldriver to the surgical tool in the surgical tool readiness state using anear-field wireless power transfer system.

Surgical Tool Release State

The methods described here may also control a tool driver in response tooperator release of a surgical tool and/or sterile adapter from a tooldriver. Generally, the operator may detach one or more of the surgicaltool and sterile adapter from the tool driver through partial detachment(e.g., by actuating a surgical tool release mechanism) or fulldetachment (e.g., physical removal by lifting and/or pulling) of thesurgical tool and/or sterile adapter from the tool driver. Partialdetachment may be analogous to partial attachment. For example, theoperator may detach the sterile adapter (having the surgical toolpartially or fully attached thereon) from the tool driver (232) totransition from either the tool engagement state (208) or tool readinessstate (210) to the surgical tool release state (212). The sterileadapter in the surgical tool release state (212) may be partiallydetached so as to lie on the tool driver but not output torquecommunicated by the tool driver. The operator is then able to whollyremove the surgical tool and sterile adapter from the tool driver totransition from the surgical tool release state (212) to the surgicaltool removed state (214).

As shown in FIG. 2, the surgical tool that is partially attached (e.g.,in the tool engagement state (208)) may transition to the surgical toolrelease state (212) either through partial detachment of the sterileadapter from the tool driver (232) or partial detachment of the surgicaltool from the sterile adapter (234). For example, when an operatordetaches the surgical tool from the surgical system (e.g., for toolswitching), the operator may actuate a tool release mechanism (notshown) on the surgical tool to bias a portion of the surgical tool awayfrom the sterile adapter. That is, an actuation mechanism (e.g., lever,button) of the surgical tool may release and/or partially separate thesurgical tool from of the sterile adapter. This corresponds totransition from either the tool engagement state (208) or tool readinessstate (210) to a surgical tool release state (212). In some variations,transition from either the tool engagement state (208) or the toolreadiness state (210) to the tool release state (212) may correspond togeneration of a sensor signal from one or more surgical tool sensorscorresponding to detachment between the surgical tool and the sterileadapter (234). For example, one or more projections (e.g., biasing pegs)of the tool driver may generate a sensor signal corresponding to atleast one projection being biased toward a surface of the tool driver(e.g., the sterile adapter partially exerting a downward force againstthe tool driver) when being detached.

In some variations, a second surgical tool sensor (e.g., proximitysensor, magnetic field transducer, Hall effect sensor) disposed on adistal end of the tool driver may generate a sensor signal correspondingto the presence of the surgical tool. This signal may indicate that thesurgical tool is at least in partial contact with the sterile adapter. Asterile adapter sensor may generate a sensor signal corresponding toattachment between the tool driver and the sterile adapter. Thecombination of these surgical tool and sterile adapter sensor signalsmay be used by the controller to transition the system to the surgicaltool release state (212). In some variations, the electroniccommunication devices of the tool driver and surgical tool maycommunicate and/or transfer power with each other as they are stillwithin close proximity to each other.

In some variations, the sterile adapter may be partially detached fromthe tool driver by lifting up and separating (e.g., unlocking) a distalend of the sterile adapter from the tool driver. For example, transitionfrom the tool engagement state (208) or the tool readiness state (210)to the tool release state (212) may correspond to generation of a sensorsignal from a sterile adaptor sensor corresponding to detachment betweenthe sterile adapter and the tool driver (232). In this state, thesurgical tool may still be fully or partially attached to the sterileadapter. Likewise, one or more surgical tool sensors may output a sensorsignal corresponding to detachment between the surgical tool and thetool driver. In response, the tool driver may be inhibited from drivingan output drive. This combination of sensor signals may comprise partialdetachment. For example, the sterile adapter may lie on the tool driverbut be functionally decoupled from the tool driver. In response to thetool release state (212), a controller may inhibit actuation of therotatable output drives of the tool driver.

In some variations, the tool driver may output a sixth light pattern inresponse to the partial detachment state. In some variations, one ormore of the tool driver and sterile adapter may output a fast pulse ofcolored light (e.g., red light) at a predetermined light intensity usingone or more optical waveguides of the tool driver and sterile adapter.For example, the sixth light pattern may comprise pulses of light havinga duration of less than about half a second (e.g., about ¼ second). Insome variations, detachment of the surgical tool from the sterileadapter may mechanically decouple the third optical waveguide of thesurgical tool from the second optical waveguide of the sterile adaptersuch that light generated by the tool driver may be distributed to andoutput only by the first optical waveguide of the tool driver and/orsecond optical waveguide of the sterile adapter. This may allow anoperator to quickly confirm the tool release state (212) based on whichsystem component is emitting light.

Additionally or alternatively, a display device may output text or animage indicating that the surgical tool is partially detached from thesterile adapter or tool driver in the tool release state (212). Forexample, a user console coupled to the system may display a message tothe operator such as “Surgical tool disengaged, please remove thesurgical tool,” “Sterile adapter disengaged, please remove the sterileadapter,” and/or “Do you wish to remove the surgical tool?” In somevariations, an audio device may output a sixth audio patterncorresponding to the tool release state (212). For example, the audiodevice may output a set of fast, short bings at a predeterminedfrequency (different from the frequency of the second and fourth audiopattern) and volume for a predetermined length of time. A haptic devicemay output a sixth haptic pattern corresponding to the tool engagementstate (208). For example, a haptic device of the tool driver may outputa small vibration. In other variations, the audio device may output themessage displayed by the user console and/or verbally describe tooldriver response to operator detachment.

Surgical Tool Removed State

An operator may fully detach the surgical tool and/or sterile adapterfrom the tool driver. In response, a controller may determine that thesystem transitions from the surgical tool release state (212) to thesurgical tool removed state (214) corresponding to complete detachmentof the surgical tool from the tool driver (236). Transition from thetool release state (212) to the tool removed state (214) may be based ongeneration of a sensor signal from one or more surgical tool sensorscorresponding to detachment of the surgical tool from the tool driver(236). For example, one or more biased projections of the tool drivermay generate a sensor signal corresponding to the surgical tool beingwithdrawn from contact with the projections of the tool driver.Furthermore, a second surgical tool sensor disposed on a distal end ofthe tool driver may output a sensor signal corresponding to the absenceof the surgical tool when a magnetic projection of the surgical tool isnot detected. The combination of these surgical tool sensor signals maybe used by the controller to transition the system to the tool removedstate (214). In some variations, electronic communication devices of thetool driver and surgical tool may move out of range of each other in theremoved state (214).

In response to the surgical tool removed state (214), the controller mayinhibit actuation of the rotatable output drives of the tool driver. Insome variations, the tool driver may output a seventh light pattern inresponse to tool removal. In some variations, one or more of the tooldriver and sterile adapter may output solid colored light (e.g., bluelight) at a predetermined light intensity using respective opticalwaveguides of the tool driver and/or sterile adapter.

Additionally or alternatively, a display device may output text or animage indicating that the surgical tool is removed from the tool driverin the tool removed state (214). For example, a user console coupled tothe system may display a message to the operator such as “Surgical toolremoved” and/or “Please attach a surgical tool.” In some variations,audio and haptic output may be inhibited in the tool removed state(214). In other variations, the audio device may output the messagedisplayed by the user console and/or verbally describe the tool driverresponse to operator detachment.

Once a surgical tool is removed, the operator may either attach anothersurgical tool and/or sterile adapter to the tool driver. For example,the controller may transition the system from the tool removed state(214) to the sterile adapter ready state (202) when a sensor signalgenerated by a sterile adaptor sensor corresponds to detachment betweenthe sterile adapter and the tool driver (238). The tool driver may beinhibited from driving an output drive in the sterile adapter detachmentstate (238). In some variations, one or more of visual, audio, andhaptic output may also be inhibited when the sterile adapter is detached(238).

In some variations, the controller may transition from a tool removedstate (214) to a tool loading readiness state (206). Transition from thetool removed state (214) to the tool loading readiness state (206) maybe triggered by a sensor signal generated by a sterile adaptor sensorcorresponding to full attachment between the sterile adapter and thetool driver (240). In response to sterile adapter attachment (240), acontroller may inhibit actuation of the rotatable output drives of thetool driver. In some variations, the tool driver may output a thirdlight pattern in response to the sterile adapter attachment state (240).For example, the tool driver may output solid colored light (e.g., bluelight) at a predetermined light intensity using an optical waveguide ofthe tool driver and/or sterile adapter.

Additionally or alternatively, a display device may output text or animage indicating that the system is ready for attachment of a surgicaltool to the sterile adapter and tool driver. For example, a user consolecoupled to the system may display a message to the operator such as“Please attach a surgical tool to the tool driver” and/or “Ready fortool loading.” In some variations, an audio device may output the thirdaudio pattern corresponding to the tool loading readiness state (206) asdescribed herein. Haptic output may be inhibited as in the third hapticpattern.

In some variations, control of the tool driver may be based onattachment state and time. For example, if partial attachment of one ormore of a sterile adapter and surgical tool to a tool driver does nottransition to full attachment within a predetermined period of timeand/or a predetermined number of attempts, then a controller may inhibittool driver output and notify the operator of the attachment error. Inresponse, the operator may repeat the attachment process.

II. Devices

A robotic surgical system may include one or more of the componentsnecessary to perform robotic surgery using the devices as describedherein. Generally, the devices described herein for use in a roboticsurgical system may include one or more of a tool driver, a sterileadapter, and a surgical tool. The tool driver may include at least onerotatable output drive configured to communicate torque to the surgicaltool through the sterile adapter. The sterile adapter may include aframe configured to be interposed between the tool driver and thesurgical tool. A plate assembly may be coupled to the frame and at leastone rotatable coupler may be supported by the plate assembly andconfigured to communicate the torque from the output drive of the tooldriver to the surgical tool. The surgical tool may include at least oneinput drive configured to receive the torque communicated from the tooldriver. The surgical tool may further include an end effectoroperatively coupled to the input drive.

In some variations, the tool driver may include an illumination sourceconfigured to emit light and an optical waveguide configured topropagate the emitted light to a sterile adapter. The sterile adapterand surgical tool may include respective optical waveguides configuredto receive, propagate, and distribute the received light. In somevariations, the tool driver may include at least one sterile adaptersensor and surgical tool sensor configured to generate a sensor signalused in turn to generate attachment data. The tool driver and surgicalmay each further comprise an electronic device configured for wirelesscommunication and/or wireless power transfer. The electronic devices maybe disposed in respective housings such that the electronic devices arein close proximity to each other when the tool driver, sterile adapter,and surgical tool are attached to each other.

Optical Waveguide

The tool driver, sterile adapter, and surgical tool as described hereinmay include one or more output devices configured to communicateinformation to an operator such as an attachment state, system or devicestate, and other information (e.g., patient data, procedure data, etc.).Information may be communicated visually by one or more of the tooldriver, sterile adapter, and surgical tool and provide an intuitiveindication of the attachment state of the surgical system to aid inefficient tool switching and sterile barrier formation. For example, oneor more of the tool driver, sterile adapter, and surgical tool mayinclude an optical waveguide (e.g., light pipe, light distributionguide, etc.) for allowing the operator to visualize attachment stateinformation generated by the system. One or more optical waveguides mayreceive light from a light source (e.g., illumination source of a tooldriver) using a predetermined combination of light output parameters(e.g., wavelength, frequency, intensity, pattern, duration) to confirm aformation state of the sterile barrier and/or robotic surgical system.

In some variations, an optical waveguide may be configured to receiveand propagate light from an illumination source upon mechanicalattachment to another optical waveguide of the robotic surgical systemsuch that they are in optical communication. For example, a tool driveroptical waveguide may be configured to output light to an input of asterile adapter optical waveguide upon attachment to the tool driver.That is, light emitted and propagated by the tool driver may be receivedby the sterile adapter only after the sterile adapter is properlyattached to the tool driver. This allows an operator to easily confirman attachment state based on light output from the set of opticalwaveguides. The optical waveguides may be formed integral with thehousings of the system to simplify manufacturing and allowing for acompact design and minimal power usage. Additionally or alternatively,the system may include a user console having additional visual outputdevices (e.g., display device). In some variations, the operator mayreceive audio and haptic feedback, as described herein, corresponding tothe attachment state of the system.

A. Tool Driver

FIG. 3A is a perspective view of a tool driver (310) comprising a firstoptical waveguide (320) for communicating to a user (e.g., an operator)an attachment state of the system using outputted light. As shown in thevariation depicted in FIG. 3A, the tool driver (310) may comprise afirst housing (312), a set of surgical tool sensors (314), and a set ofrotatable output drives (316). The set of output drives (316) may besupported by the first housing (312) and may be configured tocommunicate torque to a surgical tool through a sterile adapter (shownin FIGS. 3B and 3C). The tool driver (310) may be coupled to, forexample, a distal end of a robotic arm (not shown). The first housing(312) may comprise a first optical waveguide (320). An optical waveguidemay refer to a physical structure that guides electromagnetic waves suchas visible light spectrum waves to passively propagate and distributereceived electromagnetic waves. Non-limiting examples of opticalwaveguides include optical fiber, rectangular waveguides, light tubes,light pipes, combinations thereof, or the like. For example, light pipesmay comprise hollow structures with a reflective lining or transparentsolids configured to propagate light through total internal reflection.The optical waveguides described herein may be made of any suitablematerial or combination of materials. For example, in some variations,the optical waveguide may be made from optical-grade polycarbonate. Insome variations, the housings and frames as described herein may beco-injected molded to form the optical waveguides. In other variations,the optical waveguides may be formed separately and coupled to arespective housing or frame.

As shown in FIG. 3A, the first optical waveguide (320) may be disposedalong an exterior surface of the first housing (312). For example, thefirst optical waveguide (320) may be flush with an exterior surface ofthe first housing (312). In another example, the first optical waveguide(320) may be at least partially recessed or at least partially projectedfrom the exterior surface of the first housing (312). In somevariations, the first optical waveguide (320) may comprise a pluralityof portions (e.g., disposed on opposite sides of the tool driver (310)).For example, as shown in FIG. 3A, the first optical waveguide (320) mayinclude a strip located at least in part on a proximal end of the firsthousing (312). The strip may include a first end extending at leastpartially onto a first side (e.g., left side) of the first housing (312)and a second end extending at least partially onto a second side (e.g.,right side) of the first housing (312). As another example, the firstoptical waveguide (320) may cover a substantial portion of the exteriorof the first housing (312) (e.g., a proximal portion, side portions).

In some variations, the optical waveguides described herein may compriseone or more portions configured to emit light. For example, at least oneof the portions may comprise one or more shapes including, for example,a circle, triangle, rectangle, diamond, polygon, symbol (e.g.,plus/minus sign, arrow, lock, etc.), combinations thereof, or the like.For example, the first optical waveguide (320) may comprise threecircles on each of the first and second sides of the first housing(312). The circles may be coupled to corresponding illumination sources,as described in detail herein, and configured to output lightcorresponding to a respective status of a tool driver, sterile adapter,and surgical tool. For example, a first circle may pulse blue lightwhile a second and third circle may emit a solid red light when the tooldriver is operational and in a sterile adapter ready state (202). Theselight patterns may correspond to the tool driver in a ready state andthe sterile adapter and surgical tool unattached to the tool driver. Insome variations, the first optical waveguide (320) may be located on thefirst housing (312) so as to be easily viewed simultaneously frommultiple vantage points.

In some variations, the optical waveguides described herein may comprisea surface texture including, for example, a multi-faceted surfaceconfigured to increase visibility from predetermined vantage points. Forexample, the first optical waveguide (320) may comprise a convex shape.

The housing (312) may further comprise one or more illumination sources(not shown) coupled to the first optical waveguide (320). For example,the illumination source may be disposed at one or more of a left side,right side, proximal end, and distal end of the housing. Theillumination source may be coupled to a power source through a roboticarm and configured to emit light using a predetermined combination oflight output parameters (e.g., wavelength, frequency, intensity,pattern, duration, etc.). For example, the illumination source may becontrolled by a controller to emit a plurality of light patterns havingdifferent colors corresponding to different attachment states, asdescribed herein. In some variations, a characteristic of the light(e.g., color, pattern, etc.) may correspond to an attachment statebetween at least two of the tool driver, the sterile adapter, and thesurgical tool, as described for example with respect to FIG. 2.Non-limiting examples of an illumination source include incandescent,electric discharge (e.g., excimer lamp, fluorescent lamp, electricalgas-discharge lamp, plasma lamp, etc.), electroluminescence (e.g.,light-emitting diodes, organic light-emitting diodes, laser, etc.),induction lighting, and fiber optics. In FIG. 3A, the illuminationsource may be disposed within the first housing (312) but in somevariations may be disposed external to the first housing (312). In somevariations, the illumination source may be disposed within a proximalend of the first housing (312).

The first optical waveguide (320) may be configured to receive the lightemitted by the illumination source (e.g., as a bezel or other suitablestructure located over the illumination source). In some variations, thefirst optical waveguide (320) may be configured to emit a predeterminedpercentage of light received from the illumination source and propagatethe remaining percentage of light to a second optical waveguide (340) ofa sterile adapter (330) (shown in FIG. 3B). For example, the firstoptical waveguide (320) may be configured to emit between about 10% andabout 100% of light received from the illumination source. In somevariations, the first optical waveguide (320) may be configured to emitabout 33% of received light, and the second optical waveguide (340) maybe configured to receive about 66% of the light emitted from theillumination source. In some other variations, the first opticalwaveguide (320) may be configured to emit about 50% of received light,and the second optical waveguide (340) may be configured to receiveabout 50% of the light emitted from the illumination source.

In some variations, the first optical waveguide (320) may comprise oneor more outputs configured to physically mate with corresponding inputsof the second optical waveguide (340) so as enable light transmissionbetween the first and second optical waveguides (320, 340). For example,mating between an output of the first optical waveguide (320) and acorresponding input of the second optical waveguide (340) may befacilitated with complementary and corresponding features (e.g., latch,interlocking tabs, tab-and-slot alignment features, mateable ridge andgroove interfaces, and/or other suitable mating features, etc.). In somevariations, one or more outputs of the first optical waveguide (320) mayphysically mate with corresponding inputs of the second opticalwaveguide (340) only when the tool driver and the sterile adapter areproperly (e.g., fully and operationally) engaged or attached to oneanother. For example, if the sterile adapter is only partially engagedor attached to the tool driver, the first and second optical waveguides(320, 340) may be misaligned, thereby reducing and/or preventing lightpropagation from the first optical waveguide (320) to the second opticalwaveguide (340), thereby providing a visual indicator to the operatorthat the sterile adapter (330) is not properly attached to the tooldriver (310).

When the sterile adapter (330) is attached to the tool driver (310),light emitted from an illumination source of the tool driver (310) maybe propagated through the first and second optical waveguides (320,340), as described in further detail below. In some variations, thefirst optical waveguide (320) may emit substantially all the lightreceived from the illumination source.

B. Sterile Adapter

FIG. 3B is a perspective view of a sterile adapter (330) coupled to thetool driver (310). In some variations, the sterile adapter (330) maycomprise a second optical waveguide (340) for communicating anattachment state of the system (e.g., sterile adapter) using outputtedlight to a user such as an operator. As shown in FIG. 3B, the sterileadapter (330) may comprise a frame (332), a plate assembly (334) coupledto the frame (332), and at least one rotatable coupler (336) supportedby the plate assembly (334). The plate assembly (334) may be configuredto move up and down relative to the frame (332) within a predeterminedrange of motion, and the rotatable couplers (336) may be similarlyconfigured to rotate and move up and down relative to the plate assembly(334). The sterile adapter (330) may be placed over the surgical toolsensors (314) and output drives (316). For example, when the sterileadapter (330) is attached to the tool driver (310) and surgical tool(350) (as shown in FIG. 3C), the frame (332) may be configured to beinterposed between the tool driver (310) and the surgical tool (350).The rotatable couplers (336) may be configured to communicate torquegenerated by the output drive (316) of the tool driver (310) to thesurgical tool (350).

The frame (332) may comprise a second optical waveguide (340). As shownin FIG. 3B, the second optical waveguide (340) may be disposed along anexterior surface of the frame (332) (e.g., along a lengthwise sideportion of the sterile adapter (330), around at least a portion of theperimeter of the frame (332), etc.). For example, the second opticalwaveguide (340) may include a strip extending at least partially onto afirst side (e.g., left side) of the frame (332) and at least partiallyonto a second side (e.g., right side) of the frame (332). The strip mayfurther extend at least partially onto a distal side of the frame (332)so as to couple the first and second sides of the second opticalwaveguide (340). As depicted, the second optical waveguide (340) may beflush with the frame (332). In some variations, the second opticalwaveguide (340) may be located on the frame (332) so as to be easilyviewed simultaneously from multiple vantage points.

The second optical waveguide (340) may be configured to receive lightemitted from an output of the first optical waveguide (320). Forexample, the second optical waveguide (340) may be configured to receivelight emitted from the tool driver (310) upon attachment of the sterileadapter (330) to the tool driver (310), such that the second opticalwaveguide (340) distributes light (e.g., becomes illuminated) via lightemitted from the tool driver (310) and propagated by the first opticalwaveguide (320) to the second optical waveguide (340). In somevariations, the second optical waveguide (340) may be configured to emita predetermined percentage of light received from the first opticalwaveguide (320) and propagate the remaining percentage of light to athird optical waveguide (360) of a surgical tool (350) (shown in FIG.3C). In some variations, the second optical waveguide (340) may beconfigured to emit about 33% of the light emitted from the illuminationsource, and the third optical waveguide (360) may be configured to emitabout 33% of the light emitted from the illumination source. In someother variations, the second optical waveguide (340) may be configuredto emit about 50% of the light emitted from the illumination source.

In some variations, the second optical waveguide (340) may comprise oneor more outputs configured to physically mate with corresponding inputsof a third optical waveguide (360) (e.g., in a manner similar to matingbetween the first and second optical waveguides, as described herein).For example, mating between an output of the second optical waveguide(340) and a corresponding input of the third optical waveguide (360) maybe facilitated with complementary and corresponding features (e.g.,interlocking tabs, tab-and-slot alignment features, mateable ridge andgroove interfaces, and/or other suitable mating features, etc.). In somevariations, one or more outputs of the second optical waveguide (340)may physically mate with corresponding inputs of the third opticalwaveguide (360) only when the sterile adapter and surgical tool areproperly (e.g., fully and operationally) engaged or attached to oneanother. For example, if the surgical tool (350) is only partiallyengaged or attached to the sterile adapter (330), the second and thirdoptical waveguides (340, 360) may be misaligned, thereby preventinglight propagation from the second optical waveguide (340) to the thirdoptical waveguide (360), thereby providing a visual indicator that thesurgical tool (350) is not properly attached to the sterile adapter(330).

When the surgical tool (350) is attached to the sterile adapter (330)and the sterile adapter (330) is attached to the tool driver (310),light emitted from an illumination source of the tool driver (310) maybe propagated through the first, second, and third optical waveguides(320, 340, 360). In some variations, the second optical waveguide (340)may emit substantially all the light received from the first opticalwaveguide (320).

In some variations, the sterile adapter (330) may comprise a secondillumination source (not shown) such that the second optical waveguide(340) may be configured to receive the light emitted by the secondillumination source. In some of these variations, the second opticalwaveguide (340) may receive light only from the second illuminationsource and not the first illumination source of the tool driver (310).In some variations, the second illumination source may be batterypowered. In some variations, the second optical waveguide (340) may beconfigured to emit a predetermined percentage of light received from thesecond illumination source and propagate the remaining percentage oflight to the third optical waveguide (360). For example, the secondoptical waveguide (340) may be configured to emit between about 10% andabout 100% of light received from the second illumination source. Insome other variations, the second optical waveguide (340) may beconfigured to emit about 50% of received light, and the third opticalwaveguide (360) may be configured to receive about 50% of the lightemitted from the second illumination source. In some variations, thesecond optical waveguide (340) and second illumination source may beconfigured to propagate light to the first and third optical waveguides(320, 360). In some of these variations, the second optical waveguide(320) may be configured to emit about 33% of received light, and thefirst and third optical waveguides (320, 360) may be configured to eachemit about 33% of the light emitted from the second illumination source.

In some variations, the sterile adapter (330) may comprise a switchconfigured to activate the second illumination source upon physicalattachment of the second optical waveguide (340) to at least a portionof the tool driver (e.g., a distal end of the tool driver, first opticalwaveguide, etc.). The switch may be, for example, a conductive contactswitch, mechanical contact switch (e.g., slide switch), and the like.Accordingly, the second optical waveguide (340) may emit light receivedfrom the second illumination source only when the tool driver (310) andthe sterile adapter (330) are properly (e.g., fully and operationally)attached engaged or attached to each other and the switch is activated.

C. Surgical Tool

FIG. 3C is a perspective view of a surgical tool (350) coupled to thesterile adapter (330) and tool driver (310). In some variations, thesurgical tool (350) may comprise a third optical waveguide (360) forcommunicating an attachment state to an operator. As shown in FIG. 3C,the surgical tool (350) may comprise a second housing (352) configuredto couple to the sterile adapter (330). The surgical tool (350) maycomprise at least one input drive (not shown) supported by the secondhousing (352) and configured to receive the torque communicated from theoutput drive of the tool driver (310). The surgical tool (350) mayfurther comprise an end effector (not shown) that may extend from thesecond housing (352) and be operatively coupled to at least one inputdrive.

The second housing (352) may comprise a third optical waveguide (360)configured to receive light from the second optical waveguide (340). Asshown in FIG. 3C, the third optical waveguide (360) may be disposedalong an exterior surface of the second housing (352) (e.g., extendingwidthwise and perpendicular to the second optical waveguide (340) of thesterile adapter (330)). For example, the third optical waveguide (360)may include a strip extending at least partially onto a first side(e.g., left side) of the second housing (352) and at least partiallyonto a second side (e.g., right side) of the second housing (352). Thestrip may further extend at least partially onto a third side (e.g., topside) of the second housing (352) so as to couple the first and secondsides of the third optical waveguide (360).

The third optical waveguide (360) may be configured to receive lightemitted from an output of the second optical waveguide (340) of thesterile adapter (330). For example, the third optical waveguide (360)may be configured to receive light emitted from the tool driver (310)upon attachment of the surgical tool (350) to the sterile adapter (330)when the sterile adapter (330) is attached to the tool driver (310),such that the third optical waveguide (360) distributes light (e.g.,becomes illuminated) via light emitted from the tool driver (310) andpropagated by the first and second optical waveguides (320, 340) to thethird optical waveguide (360). In other words, when the surgical tool(350) is attached to the sterile adapter (330) and the sterile adapter(330) is attached to the tool driver (310), light emitted from anillumination source of the tool driver (310) may be propagated throughthe first, second, and third optical waveguides (320, 340, 360). In somevariations, the third optical waveguide (360) may emit substantially allthe light received from the second optical waveguide (340).

In some variations, the surgical tool (350) may comprise a thirdillumination source (not shown) such that the third optical waveguide(360) may be configured to receive the light emitted by the thirdillumination source. In some of these variations, the third opticalwaveguide (360) may receive light only from the third illuminationsource and not the first and/or second illumination sources. In somevariations, the third illumination source may be battery powered orwirelessly powered using an electronic device as described in detailwith respect to FIG. 8. In some variations, the third optical waveguide(360) may emit substantially all the light emitted from the thirdillumination source. In some variations, the third optical waveguide(360) may be configured to emit a predetermined percentage of lightreceived from the third illumination source and propagate the remainingpercentage of light to the first and/or second optical waveguides (320,340). For example, the third optical waveguide (360) may be configuredto emit between about 10% and about 100% of light received from thethird illumination source. In some other variations, the third opticalwaveguide (360) may be configured to emit about 50% of emitted light,and the second optical waveguide (340) may be configured to emit about50% of the light emitted from the third illumination source. In somevariations, the third optical waveguide (360) and third illuminationsource may be configured to propagate light to the second and/or firstoptical waveguides (340, 320). In some of these variations, the thirdoptical waveguide (360) may be configured to emit about 33% of emittedlight, and the first and second optical waveguides (320, 340) may beconfigured to each emit about 33% of the light emitted from the thirdillumination source.

In some variations, the surgical tool (350) may comprise a switchconfigured to activate the third illumination source upon physicalattachment of the third optical waveguide (360) to at least a portion ofthe sterile adapter (e.g., a distal end of the sterile adapter, secondoptical waveguide, etc.). The switch may be, for example, a conductivecontact switch, mechanical contact switch (e.g., slide switch), and thelike. Accordingly, the third optical waveguide (360) may emit lightreceived from the third illumination source only when the surgical tool(350) and the sterile adapter (330) are properly (e.g., fully andoperationally) attached engaged or attached to each other and the switchis activated.

In some variations, the optical waveguides of the tool driver (310),sterile adapter (330), and surgical tool (350) may be disposed alongdifferent portions of the system to aid identification of the attacheddevice component. For example, the first optical waveguide (320) may bedisposed at an end of the tool driver (310), the second opticalwaveguide (340) may be disposed along a length of the sterile adapter(330), and the third optical waveguide (360) may be disposedperpendicular to the second optical waveguide (340) and across a top ofthe surgical tool (350). In other variations, three optical waveguidesmay disposed respectively at a distal end, intermediate portion, andproximal end.

Additionally or alternatively, one or more optical waveguides may bedisposed along one or more of a robotic arm, display, surgical platform,or the like. For example, an optical waveguide disposed on one or moreportions of a robotic arm may be configured to communicate an attachmentstate of the robotic arm to a tool driver. As another example, asurgical platform may comprise one or more optical waveguides disposedalong a perimeter of a top surface of the platform and may be configuredto communicate one or more of an operational state, attachment state,procedure state, or the like, of the robotic surgical system. Any of theoptical waveguides as described herein may communicate a state of any ofthe components of the system.

Surgical Tool Sensors

The tool driver as described herein may include one or more surgicaltool sensors configured to generate a sensor signal corresponding to anattachment state (e.g., partial attachment, full attachment, partialdetachment, full detachment, improper attachment) between the tooldriver and surgical tool. The surgical tool sensors described herein maybe used to directly or indirectly determine a proximity of a surgicaltool to the tool driver. The attachment state may be used to control thetool driver and/or notified to an operator. The surgical tool sensor maybe, for example, a proximity sensor that may be used to determine aposition of the surgical tool relative to the tool driver. For example,the surgical tool sensor may be disposed in one or more projections(e.g., cylindrical pegs) configured to bias away from a surface of thetool driver housing and toward a surgical tool. When a sterile adapteris coupled to the tool driver for attachment, the projections may beconfigured to contact the sterile adapter to urge a plate assemblyupward and away from the tool driver. When a surgical tool is attachedto the sterile adapter, the surgical tool will urge the plate assemblytoward the tool driver and reduce projection height. By placing asurgical tool sensor within one or more of the projections, a sensorsignal may be generated that corresponds to a change in height of theprojection and an attachment state between the tool driver and surgicaltool.

FIGS. 4A-4E are illustrative views of an exemplary variation of a tooldriver (400) configured to attach to a surgical tool via a sterileadapter. FIG. 4A is a plan view of the tool driver (400). The tooldriver (400) may comprise a first housing (402) configured to attach toa surgical tool via a sterile adapter. The tool driver (400) maycomprise one or more rotatable output drives (410) supported by thefirst housing (402) where the output drives (410) may be configured tocommunicate torque to an input drive of the surgical tool through asterile adapter. One or more of the output drives (410) may comprise oneor more of a torque sensor (440) and rotary output encoder (460)configured to generate one or more sensor signals used to determine achange in torque of the output drive (410). In some variations, asterile adapter sensor may comprise at least one of the torque sensor(440) and rotary output encoder (460) (FIGS. 4B and 4C). A change intorque may correspond to a change in engagement (e.g., attachment,detachment) between a rotatable coupler of a sterile adapter and therotatable output drive (410) of the tool driver (400). FIG. 4A depictssix output drives (410) arranged on a surface of the first housing (402)in a bilaterally symmetric arrangement. Similarly, four projections(420) may be arranged in a bilaterally symmetric arrangement and mayalso be disposed between pairs of the output drives (410). Thisarrangement may aid detection of lateral and/or longitudinalmisalignment of one or more of the sterile adapter and tool driver tothe tool driver (400). Sensor signals from each of the projections (420)may be used together to generate attachment data. Although FIG. 4Adepicts a tool driver with six rotary output drives (410) and fourprojections (420), it should be understood that in other variations, thetool driver may include fewer or more output drives (410) and/orprojections (420). Additionally or alternatively, the tool driver (400)may include at least one linear output drive (e.g., a drive providing anaxially-moving output), such as described in U.S. patent applicationSer. No. 15/803,659, filed on Nov. 3, 2017 and entitled “TOOL DRIVERWITH LINEAR DRIVES FOR USE IN ROBOTIC SURGERY,” which is incorporatedherein in its entirety by reference.

Although some variations of the tool driver (400) may comprise a singleprojection (420) having a surgical tool sensor (424), a plurality ofspaced apart first surgical tool sensors (424) may allow the system todetermine an orientation of a plate assembly relative to the sterileadapter frame. That is, knowledge of an attachment state between thesterile adapter and tool driver (400) may be improved by using aplurality of first surgical tool sensors. For example, a surgical toolmay be improperly attached to a sterile adapter and tool driver (400)when fewer than four projections (420) are pressed down to apredetermined height. If only three projections are urged downward withthe fourth projection in a higher position, then the sensor signaloutput by the first surgical tool sensors (424) may correspond to animproper attachment state where the surgical tool is askew relative tothe sterile adapter. In this position, one or more of the rotatablecouplers (410) may be unable to communicate torque to the input drive ofthe surgical tool.

FIGS. 4B-4C are cross-sectional side views of the tool driver (400)along the H-H lines depicted in FIG. 4A. The tool driver (400) maycomprise at least one rotatable output drive (410) supported by thefirst housing (402) and at least one projection (420) extending from asurface of the first housing (402) and configured to bias away from thesurface, as shown in FIG. 4B. In some variations, the projection (420)may comprise a first surgical tool sensor (424) configured to generate asensor signal comprising at least one attachment state between the tooldriver (400) and the surgical tool. In some variations, the firstsurgical tool sensor (424) may be a proximity sensor configured todetermine a proximity of first end of the projection (420) relative tothe second end of the projection (420). As shown in FIGS. 4D and 4E, theproximity sensor may comprise a magnet (422) coupled to a first end ofthe projection (420) disposed on an exterior side of the first housing(402) and a magnetic field transducer (425) coupled to a second end ofthe projection (420) disposed on an interior side of the first housing(402). In some variations, the magnetic field transducer may be ananalog sensor. In some variations, the projection (420) may comprise acomplaint material configured to bias the first end of the projection(420) away from the first housing (402). For example, the compliantmaterial may be a coil spring (414) (FIGS. 4D and 4E) coupled betweenthe first end of the projection (420) and a surface of the first housing(402). In other variations, the projection (420) may comprise a leafspring.

FIGS. 4A, 4B, and 4D illustrate the projections (420) in a firstconfiguration where the projection (420) is fully biased away from asurface of the housing (402). For example, in the first configuration,the projection (420) is not in contact with either of the sterileadapter or the surgical tool. The first configuration of the projection(420) corresponds to, for example, a detachment state between the tooldriver, sterile adapter, and surgical tool. FIGS. 4A, 4C, and 4Eillustrate the projections (420) in a second configuration where theprojection (420) is fully retracted toward the surface of the firsthousing (402) due to a compressive force such as from attachment of asurgical tool and sterile adapter (not shown). The second configurationof the projection (420) corresponds to, for example, an attachment stateof the sterile adapter and/or surgical tool.

In some variations, an attachment state may correspond to a position ofthe projection (420) over time. For example, when the first surgicaltool sensor (420) is in a first or second configuration for apredetermined amount of time, the sensor signal may correspond to eithera detached state or attached state. A sterile adapter may be in apartial attachment state when the projection (420) transitions quicklyfrom the first configuration to the second configuration and back to thefirst configuration. For example, an operator may attach a sterileadapter to a tool driver by rotating the sterile adaptor over theprojections (420) to urge the projection toward the secondconfiguration. Once the frame of the sterile adapter is latched into thetool driver, then the projections (420) may be biased toward the firstconfiguration.

In some variations, a proximity sensor of a projection may comprise aHall effect sensor. The magnet may be made of any suitable material orcombination of materials. For example, in some variations, the magnetmay be a permanent magnet, ferromagnetic magnetic, and paramagneticmagnet, and may be made from aluminum, platinum, iron, nickel, cobalt,copper, titanium, alloys or combinations thereof, or the like.

In some variations, a tool driver may comprise at least one secondsurgical tool sensor configured to directly sense a location of asurgical tool used for generating a sensor signal corresponding to anattachment state between the tool driver and surgical tool. FIG. 5A is aplan view of a tool driver (510) comprising a first housing (512), a setof output drives (514), and a set of projections (516) disposed on asurface of the first housing (512), a sterile adapter sensor (518)disposed on a distal end of the first housing (512), and a proximal end(522) of the first housing (512). In some variations, an electronicdevice (not shown) may be depicted within the proximal end (522). FIG.5B is a cross-sectional side view of the tool driver (500) along the M-Mline depicted in FIG. 5A. FIG. 5B depicts a second surgical tool sensor(520) disposed within a distal end of the first housing (512).

In some variations, a sterile adapter may be configured to attach to thetool driver (510) by attaching a proximal end of the sterile adapteronto a proximal end (522) of the tool driver before attaching a distalend of the sterile adapter onto a distal end of the tool driver (510).Likewise, a proximal end of a surgical tool may be attached to aproximal end of the sterile adapter before attaching a distal end of thesurgical tool onto a distal end of the sterile adapter. Accordingly,when the second surgical tool sensor (520) of the tool driver (510)senses a presence of the distal end of the surgical tool, the sensorsignal may correspond to attachment between the surgical tool, sterileadapter, and tool driver (510).

FIG. 5C is a detailed cross-sectional side view of the tool driver (510)depicted in FIG. 5B and shows a distal end of the surgical tool (530)within sensor range of the second surgical tool sensor (520). In FIG.5C, a second surgical tool sensor (520) may be disposed within a distalend of the first housing (512) of the tool driver (510). In somevariations, the second surgical tool sensor (520) may comprise aproximity sensor. For example, the proximity sensor may be a magneticfield transducer such as a Hall effect sensor. Opposite the secondsurgical tool sensor (520), a distal end of the surgical tool (530) maycomprise a second housing (532) configured to attach to a sterileadapter (not shown for the sake of clarity). The second housing (532) ofthe surgical tool (530) may comprise a magnetic projection (542)configured to mate with a corresponding recess in a sterile adapter. Themagnetic projection (542) may comprise a magnet as described herein. Themagnetic projection (542) may comprise a first tapered surface (544) anda second tapered surface (546) opposite the first tapered surface (544).

A sterile adapter engagement feature (540) may comprise the distal endof the surgical tool (530) including the magnetic projection (542). Themagnetic projection (542) may extend from a surface of the surgical tool(530) and be configured to slide over portions of the sterile adapterand be placed within a recess of the sterile adapter, as described inmore detail with respect to FIGS. 6A and 6B. As discussed herein, thesurgical tool (530) may comprise at least one input drive supported by ahousing of the surgical tool (530) and may be configured to receivetorque communicated from an output drive (514) of the tool driver (510)through the sterile adapter. An end effector (not shown) may extend fromthe surgical tool housing and be operatively coupled to the input drive.

FIGS. 6A-6B are cross-sectional side views of a sterile adapter (610)and a surgical tool (620) comprising corresponding engagement featuresfor mating the surgical tool (620) to the sterile adapter (610) in adesired orientation. For example, one or more engagement features may beconfigured to prevent an operator from attaching a distal end of thesurgical tool to a proximal end of the sterile adapter. In somevariations, a sterile adapter engagement feature (640) of the surgicaltool (620) may comprise a magnetic projection (642) (see FIG. 6B)comprising a magnet as described herein and configured to be directlysensed by a second surgical tool sensor (690) of the tool driver. Forexample, the second surgical tool sensor (690) may comprise at least oneof an inductive sensor, optical sensor, magnetic sensor, conductivecontact switch, and/or mechanical contact switch. As depicted in FIG.6A, a surgical tool (620) may comprise a sterile adapter engagementfeature (640) that may protrude from a surface of the surgical tool(620) and be configured to engage with a surface of a sterile adapter(610). The sterile adapter engagement feature (640) and surgical toolengagement feature (650) may be disposed at respective distal ends ofthe surgical tool (620) and sterile adapter (610). The sterile adapter(610) may comprise a plate assembly (680) coupled to a frame (670), anda surgical tool engagement feature (650) disposed in the plate assembly(680) and configured to mate with the sterile adapter engagement feature(640). In some variations, a proximal end of the surgical tool (620) maycomprise a projection configured to support an electronic communicationdevice of the surgical tool (620), as discussed in more detail withrespect to FIG. 8.

FIG. 6B is a detailed cross-sectional view of a distal end of thesurgical tool (620) and sterile adapter (610). As discussed herein, thesterile adapter engagement feature (640) may project from a surface ofthe sterile adapter (620). In some of these variations, the sterileadapter engagement feature (640) may comprise a magnetic projection(642) comprising a first tapered surface (644) and a second taperedsurface (646) opposite the first tapered surface (644). The taperedsurfaces (644, 646) may be angled to allow the surgical tool (620) toslide over one or more portions of the sterile adapter (610) until themagnetic projection (642) mates with (e.g., slides into) the surgicaltool engagement feature (650). For example, the sterile adapterengagement feature (640) may comprise a trapezoidal shape. The surgicaltool engagement feature (650) may comprise a recess configured to holdthe sterile adapter engagement feature (640) and limit movement of thesurgical tool (620) relative to the sterile adapter (610). The recessmay be distal to an output drive disc (682). A second surgical toolsensor (690) of a tool driver, as described herein, may overlap (e.g.,disposed below) the surgical tool engagement feature (650). In somevariations, the surgical tool (620) and sterile adapter (610) maycomprise a plurality of spaced-apart engagement features. In somevariations, the surgical tool engagement feature (640) may comprise arecess while the sterile adapter (650) may comprise a projection.

Sterile Adapter Sensor

In some variations, a tool driver may include at least one sterileadapter sensor configured to generate a sensor signal when the sterileadapter is fully attached to the tool driver. For example, the sterileadapter sensor may generate the sensor signal when the sterile adapteris physically latched onto a distal portion of the tool driver. Thesensor signal may correspond to an attachment state (e.g., fullattachment, full detachment) between the tool driver and sterileadapter. The tool driver and sterile adapter may each be configured soas to allow only one-way engagement between the sterile adapter and tooldriver. That is, the distal end of the sterile adapter will not engage(e.g., latch into) with the tool driver unless the proximal ends of thesterile adapter and tool driver are mated to each other. The attachmentstate may be used to control the tool driver and/or notify an operatorof the attachment state of the system. The sterile adapter sensor maybe, for example, a switch sensor configured to generate a sensor signalupon physical contact with the sterile adapter.

In some variations, as shown in FIG. 4A, the first housing (402) maycomprise a sterile adapter sensor (430) disposed at a distal end of thefirst housing (402). The sterile adapter sensor (430) may be configuredto generate a sensor signal corresponding to an attachment state betweenthe tool driver (400) and a sterile adaptor (not shown for clarity).Variations of a sterile adapter sensor are described in more detailherein with respect to FIGS. 7A-7C. In some variations, a proximal end(470) of the first housing (402) may be configured to support anelectronic communication device of the tool driver (400), as describedin more detail herein with respect to FIG. 8.

FIG. 7A is a plan view of a tool driver (710) coupled to a sterileadapter (720). The sterile adapter (720) may comprise a plate assembly(724) coupled to a frame (722). The frame (722) may be configured to beinterposed between the tool driver (710) and surgical tool (not shownfor clarity). A set of rotatable couplers (726) may be supported by theplate assembly (724) and configured to communicate torque from an outputdrive (714) of the tool driver (710) to the surgical tool.

FIGS. 7B-7C are cross-sectional side views of the sterile adapter (720)and tool driver (710) along the K-K line in FIG. 7A. The tool driver(710) may comprise a housing (712) configured to couple to the sterileadapter (720). The housing (712) may comprise a sterile adapterengagement feature (740) mateable with a corresponding tool driverengagement feature (750) on the sterile adapter (720). A sterile adaptersensor (730) may be coupled to the sterile adapter engagement feature(740) and configured to generate a sensor signal when the tool driverengagement feature (750) is mated with its corresponding sterile adapterengagement feature (740). That is, the sterile adapter sensor (730) isdisposed at a location that does not generate a sensor signal until thesterile adapter is securely attached to the tool driver. In somevariations, the sterile adapter engagement feature (740) and sterileadapter sensor (730) may each be disposed on a distal end of the tooldriver (710) on a side of a tool driver housing perpendicular to therotatable output drive (714). As shown in FIG. 7C, the sterile adapterengagement feature (740) may comprise a projection, and the tool driverengagement feature (750) may comprise a recess. The projection may beconfigured (e.g., tapered) to allow the sterile adapter (720) to slideover the projection. The projection may then mate with the recess of thetool driver engagement feature (750). For example, the projection of thesterile adapter engagement feature (740) may comprise a tapered surfaceon one side and a flat surface opposite the tapered surface. The recessof the tool driver engagement feature (750) may be configured to limitmovement of the sterile adapter (720) relative to the tool driver (710).

In some variations, a distal portion of the frame (722) projectingperpendicularly from a plane of the plate assembly (724) and comprisingthe tool driver engagement feature (750) may comprise a compliantmaterial that may aid an operator in mating the sterile adapter to thetool driver using respective engagement features. In some variations,the tool driver (710) and sterile adapter (720) may comprise a pluralityof spaced-apart engagement features. In some variations, the sterileadapter engagement feature (740) may comprise a recess while the tooldriver engagement feature (740) may comprise a projection. Placing thesterile adapter engagement feature (740) and tool driver engagementfeature (750) further away from the rotatable plate assembly (724) mayhelp ensure that mating of the engagement features (740, 750)corresponds to proper attachment of the sterile adapter (720) to thetool driver (710). Accordingly, it is preferable for the engagementfeatures (740, 750) to be the final portions of the sterile adapter(720) and tool driver (710) that couple to each other when the sterileadapter (720) is attached to the tool driver (720).

In some variations, the sterile adapter sensor (730) may comprise aproximity sensor configured to detect attachment between the sterileadapter engagement feature (740) and tool driver engagement feature(750). For example, the proximity sensor may comprise at least one of aconductive contact switch, mechanical contact switch (e.g., slideswitch), Hall Effect sensor, forces sensor, optical sensor, combinationsthereof, or the like. In FIG. 7C, the sterile adapter sensor (730) maycomprise a switch (732) including a torsion spring configured to biasthe switch (732) to an initial, reset position. In some variations, theswitch (732) may be disposed adjacent to the sterile adapter engagementfeature (740) such that the switch (732) is depressed when theengagement features (740, 750) mate.

Electronic Device

In some variations, at least one of the tool driver and surgical toolmay include one or more electronic communication devices configured totransmit data to each other. Generally, a tool driver and surgical toolmay include respective communication devices in close proximity to eachother when the surgical tool is attached to the sterile adapter and tooldriver. Communication performance may depend at least in part onplacement of the communication devices within the tool driver andsurgical tool. For example, minimizing the distance between theelectronic communication devices may improve one or more ofsignal-to-noise ratio (SNR) and power efficiency. In some variations,the electronic devices may comprise a wireless power transfer system.

A. Tool Driver

In some variations, a tool driver may comprise an electroniccommunication device configured to communicate wirelessly with acorresponding electronic communication device of a surgical tool. Thismay allow the system to perform a number of functions with the surgicaltool. For example, the tool driver may communicate with the surgicaltool to identify and authenticate the surgical tool, determinecompatibility, download tool usage information (e.g., log data),configure settings of the surgical tool, communicate calibration data,or the like. FIG. 8 is a cross-sectional side view of a variation of atool driver (810) coupled to a surgical tool (850) through a sterileadapter (840). As shown in FIG. 8, the tool driver (810) may comprise afirst housing (812) configured to attach to a surgical tool (850) via asterile adapter (840). The tool driver (810) may further comprise atleast one output drive (822) coupled to a corresponding rotatable outputdrive disk (820) each supported by the first housing (812). The outputdrive (822) may be configured to communicate torque to an input drive(not shown) of the surgical tool (850) through the sterile adapter(840). The first housing (812) may comprise a first electroniccommunication device (830) disposed substantially in a plane of theoutput drive disk (820). The first electronic communication device (830)may be configured to wirelessly communicate with the surgical tool(850).

In some variations, a proximal end of the first housing (812) may beconfigured to support the first communication device (814) in a firstcommunication portion (814). For example, the proximal end of the firsthousing (812) may comprise a projection (e.g., first communicationportion (814)). The output drive disk (830) and first communicationportion (814) may have substantially the same height.

In some variations, an electronic communication device may comprise awireless communication board comprising radiofrequency (RF) circuitry(e.g., RF transceiver) including one or more of a receiver, transmitter,and/or optical (e.g., infrared) receiver and transmitter. RF circuitrymay receive and transmit RF signals (e.g., electromagnetic signals) fromthe surgical tool and other devices. The RF circuitry converts betweenelectrical signals and electromagnetic signals and communicates withother communications devices using the electromagnetic signals. The RFcircuitry may include one or more of an antenna system, an RFtransceiver, one or more amplifiers, a tuner, one or more oscillators, adigital signal processor, a CODEC chipset, a subscriber identity module(SIM) card, memory, and the like.

Short-range wireless communication using the electronic communicationdevices may use one or more communications standards, protocols andtechnologies including but not limited to Bluetooth, near-fieldcommunication (NFC), and radio-frequency identification (RFID). In somevariations, the electronic communication device may be powered by abattery.

B. Sterile Adapter

In some variations, a sterile adapter may be configured to be interposedbetween a tool driver and surgical tool and formed in such a manner asto minimize a distance between their respective electronic communicationdevices. As shown in FIG. 8, the sterile adapter (840) may comprise aframe (842) configured to be interposed between the tool driver (810)and surgical tool (850). The frame (842) may be coupled to a plateassembly (not shown in FIG. 8). The frame (842) of the sterile adapter(840) may comprise a communication portion (846) configured to support aprojection (854) of the surgical tool (850). The projection (854) may besubstantially in a plane of the plate assembly when the surgical tool(850) is attached to the sterile adapter (840) and the plate assembly isbiased toward the tool driver (810). Accordingly, when a secondelectronic communication device (832) is disposed in the projection(854), the second electronic communication device (832) may besubstantially in a plane of the plate assembly. At least one rotatablecoupler (844) may be supported by the plate assembly and configured tocommunicate torque from the output drive (822) of the tool driver (810)to the input drive of the surgical tool (850).

As shown in FIG. 8, a proximal end of the frame (842) may comprise thecommunication portion (846). In some variations, the communicationportion (846) may attach to a proximal end of the first communicationportion (814). The communication portion (846) may further support theprojection (854) of the surgical tool housing (852). In some variations,the communication portion (846) of the frame (842) may be thinner thanother portions of the frame (842) in order to reduce a distance betweenthe communication devices (830, 832). In some variations, the frame(842) of the sterile adapter (840) may be formed without thecommunication portion (846) to allow the proximal ends of the tooldriver (810) and surgical tool (850) to be brought closer together.

C. Surgical Tool

In some variations, a surgical tool may comprise an electroniccommunication device configured to communicate wirelessly with acorresponding electronic communication device of a tool driver. This mayallow the surgical tool to perform a number of functions. For example,the surgical tool may communicate with the tool driver to identify andauthenticate the tool driver and/or surgical system, determinecompatibility, communicate calibration data, or the like. As shown inFIG. 8, the surgical tool (850) may comprise a second housing (852)configured to couple to the sterile adapter (840). The second housing(852) may comprise a projection. In some variations, an end effector(not shown) may extend from the second housing (852) and be operativelycoupled to an input drive of the surgical tool (850). The input drivemay be supported by the second housing (852) and be configured toreceive torque communicated from the output drive (822) of the tooldriver (810) through the sterile adapter (840). The second housing (852)may comprise a second communication device (832) configured towirelessly communicate with the tool driver (810). The secondcommunication device (832) may be disposed in the projection (854). Thesecond communication device (832) may be of the same or differentconfiguration as the first communication device (830) described herein.

In some variations, a proximal end of the surgical tool (850) maycomprise the projection (854). For example, the projection (854) of thesurgical tool (850) may be configured to support the secondcommunication device (832). The output drive disk (830) and proximal endof the first housing (812) may have substantially the same height. Oneor more of the projection (854) and second communication device (832)may be disposed in substantially the same plane as the rotatable coupler(844). By providing the second electronic communication device (832)within the projection (854) that extends away from the surgical tool(850), the internal configuration of the surgical tool need not bemodified to accommodate the electronic communication device. In somevariations, the projection (854) having the second communication device(832) may be removably attached from the surgical tool (850). Forexample, a surface of the projection (854) facing the surgical tool(850) may comprise one or more fasteners (e.g., hooks) configured tocouple to one or more of an underside of the surgical tool (850) and theframe (842) of the sterile adapter (840).

In some variations, when the surgical tool (850) and sterile adapter(840) are attached to the tool driver (810), a distance between thefirst and second communication devices (830, 832) may be less than about10 mm. In some variations, the distance between the first and secondcommunication devices (830, 832) may be less than about 6 mm. In somevariations, the distance between the first and second communicationdevices (830, 832) may be between about 3 mm and about 6 mm. Generally,the plate assembly of the sterile adapter (840) may move relative to theframe (842) by more than about 5 mm. These short distances between theelectronic communication devices may enable wireless power transfer toone or more devices of the surgical tool, such as the communicationdevice and/or sensor. In some variations, the electronic devices maytransfer power using one or more of inductive coupling and capacitivecoupling.

III. Systems

Generally, the robotic surgical systems described herein may include arobotic arm and corresponding control system coupled to a tool driver,sterile adapter, and surgical tool. In some variations, a tool drivermay comprise one or more sensors configured to generate sensor signals.Those signals may be received by a controller and used to generateattachment data corresponding to an attachment state between the tooldriver, sterile adapter, and surgical tool. The control system mayaccordingly control one or more of the robotic arm and tool driver usingthe attachment data. As described in more detail herein, the controllermay be coupled to one or more networks using a network interface. Thecontroller may include a processor and memory coupled to a communicationinterface comprising a user interface. The controller may automaticallyperform one or more steps of a sterile barrier formation process, andthus improve a surgical tool switching process and reduce operator errorby following a proper attachment sequence for engaging the sterileadapter and surgical tool to the tool driver.

FIGS. 9A-9B are block diagrams of a variation of a robotic surgicalsystem (900). The system (900) may comprise a control system (920)configured to control one or more of a robotic arm (910), tool driver(912), sterile adapter (914), and surgical tool (916). The robotic arms(910) may be located at a surgical platform (e.g., table, bed, etc.)having attached at a distal end one or more of a tool driver (912),sterile adapter (914), and surgical tool (916) (e.g., end effector). Therobotic arm (910) may include a plurality of links that are actuated soas to position and orient the tool driver (912). The robotic arms (916)may be mounted on a table, in a cart, ceiling, sidewall, or othersuitable support surface.

In some variations, the system (900) may include one or more sensorsconfigured to generate sensor signals corresponding to an attachmentstate between two or more of the tool driver (912), sterile adapter(914), and surgical tool (916). For example, the sensors may be disposedin the tool driver and configured to sense one or more of a presence,engagement, and/or attachment of the tool driver to the sterile adapterand surgical tool. The tool driver (912), sterile adapter (914), andsurgical tool (916) may be coupled to the control system (920) throughone or more wired or wireless communication channels. Any wiredconnections may be optionally built into the floor and/or walls orceiling. The control system (920) may be coupled to one or more networks(970), databases (940), and/or servers (950). The network (970) maycomprise one or more databases (940) and servers (950). In somevariations, a remote operator (not shown) may be coupled one or morenetworks (970), databases (940), and servers (950) through a userconsole (960) (e.g., surgeon bridge). In some variations, one or more ofthe tool driver (912) and surgical tool (916) may be coupled directly toany of the network (970), database (940), server (950), or each other.Processing, data generation, and analysis may be performed at any one ofthe devices of the system (900) or distributed throughout a plurality ofdevices.

A user (such as a surgeon or other operator) may use the user console(960) to remotely manipulate the robotic arms (910) and/or surgicaltools (916) (e.g., tele-operation). The user console (960) may belocated in the same procedure room as the robotic surgical system (900),in an adjacent or nearby room, or tele-operated from a remote locationin a differently building, city, country, etc. In some variations, aplurality of user consoles (960) may be provided, for example to controladditional surgical tools, and/or to take control of one or moresurgical tools at a primary user console. The will permit, for example,a surgeon to take over or illustrate a technique during a surgicalprocedure with medical students and physicians-in-training, or to assistduring complex surgeries requiring multiple surgeons actingsimultaneously or in a coordinated manner.

Control System

The tool drivers, sterile adapters, and surgical tools as describedherein may couple to one or more control systems (e.g., computersystems) and/or networks. FIG. 9B is a block diagram of the controlsystem (920). The control system (920) may comprise a controller (922)comprising a processor (924) and a memory (926). In some variations, thecontrol system (920) may further comprise one or more of a communicationinterface (930). The controller (922) may be coupled to thecommunication interface (930) to permit an operator to remotely controlthe control system (920), robotic arm (910), tool driver (912), surgicaltool (916), sensors, and any other component of the system (900). Thecommunication interface (930) may comprise a network interface (932)configured to connect the control system (920) to another system (e.g.,Internet, remote server, database) over a wired and/or wireless network.The communication interface (930) may further comprise a user interface(934) configured to permit an operator to directly control the controlsystem (920).

A. Controller

A control system (920), as depicted in FIG. 9B, may comprise acontroller (922) in communication with the robotic surgical system (900)(e.g., robotic arm (910), tool driver (912), surgical tool (916)). Thecontroller (920) may comprise one or more processors (924) and one ormore machine-readable memories (926) in communication with the one ormore processors (924). The processor (924) may incorporate data receivedfrom memory (926) and operator input to control the system (900). Thememory (926) may further store instructions to cause the processor (924)to execute modules, processes and/or functions associated with thesystem (900). The controller (922) may be connected to one or more ofthe robotic arm (910), tool driver (912), and surgical tool (916) bywired and/or wireless communication channels. The controller (922) maybe configured to control one or more components of the system (900),such as robotic arm (910), tool driver (912), surgical tool (916),communication interface (930), and the like.

The controller (922) may be implemented consistent with numerous generalpurpose or special purpose computing systems or configurations. Variousexemplary computing systems, environments, and/or configurations thatmay be suitable for use with the systems and devices disclosed hereinmay include, but are not limited to software or other components withinor embodied on a surgeon bridge, servers or server computing devicessuch as routing/connectivity components, multiprocessor systems,microprocessor-based systems, distributed computing networks, personalcomputing devices, network appliances, portable (e.g., hand-held) orlaptop devices. Examples of portable computing devices includesmartphones, personal digital assistants (PDAs), cell phones, tabletPCs, wearable computers taking the form of smartwatches and the like,and portable or wearable augmented reality devices that interface withthe operator's environment through sensors and may use head-mounteddisplays for visualization, eye gaze tracking, and user input.

i. Processor

The processor (924) may be any suitable processing device configured torun and/or execute a set of instructions or code and may include one ormore data processors, image processors, graphics processing units,physics processing units, digital signal processors, and/or centralprocessing units. The processor (924) may be, for example, a generalpurpose processor, Field Programmable Gate Array (FPGA), an ApplicationSpecific Integrated Circuit (ASIC), or the like. The processor (924) maybe configured to run and/or execute application processes and/or othermodules, processes and/or functions associated with the system and/or anetwork associated therewith. The underlying device technologies may beprovided in a variety of component types including metal-oxidesemiconductor field-effect transistor (MOSFET) technologies likecomplementary metal-oxide semiconductor (CMOS), bipolar technologieslike emitter-coupled logic (ECL), polymer technologies (e.g.,silicon-conjugated polymer and metal-conjugated polymer-metalstructures), mixed analog and digital, combinations thereof, or thelike.

ii. Memory

In some variations, the memory (926) may include a database (not shown)and may be, for example, a random access memory (RAM), a memory buffer,a hard drive, an erasable programmable read-only memory (EPROM), anelectrically erasable read-only memory (EEPROM), a read-only memory(ROM), Flash memory, combinations thereof, or the like. As used herein,database refers to a data storage resource. The memory (926) may storeinstructions to cause the processor (924) to execute modules, processes,and/or functions associated with the control system (920), such assterile barrier formation, notification, robotic arm control, tooldriver control, surgical tool control, sensor control, sensor signalprocessing, communication, authentication, or user settings, or thelike. In some variations, storage may be network-based and accessiblefor one or more authorized users. Network-based storage may be referredto as remote data storage or cloud data storage. Sensor signal andattachment data stored in cloud data storage (e.g., database) may beaccessible to respective users via a network, such as the Internet. Insome variations, database (940) may be a cloud-based FPGA.

Some variations described herein relate to a computer storage productwith a non-transitory computer-readable medium (also may be referred toas a non-transitory processor-readable medium) having instructions orcomputer code thereon for performing various computer-implementedoperations. The computer-readable medium (or processor-readable medium)is non-transitory in the sense that it does not include transitorypropagating signals per se (e.g., a propagating electromagnetic wavecarrying information on a transmission medium such as space or a cable).The media and computer code (also may be referred to as code oralgorithm) may be those designed and constructed for a specific purposeor purposes.

Examples of non-transitory computer-readable media include, but are notlimited to, magnetic storage media such as hard disks, floppy disks, andmagnetic tape; optical storage media such as Compact Disc/Digital VideoDiscs (CD/DVDs); Compact Disc-Read Only Memories (CD-ROMs); holographicdevices; magneto-optical storage media such as optical disks; solidstate storage devices such as a solid state drive (SSD) and a solidstate hybrid drive (SSHD); carrier wave signal processing modules; andhardware devices that are specially configured to store and executeprogram code, such as Application-Specific Integrated Circuits (ASICs),Programmable Logic Devices (PLDs), Read-Only Memory (ROM), andRandom-Access Memory (RAM) devices. Other variations described hereinrelate to a computer program product, which may include, for example,the instructions and/or computer code disclosed herein.

The systems, devices, and methods described herein may be performed bysoftware (executed on hardware), hardware, or a combination thereof.Hardware modules may include, for example, a general-purpose processor(or microprocessor or microcontroller), a field programmable gate array(FPGA), an application specific integrated circuit (ASIC), or the like.Software modules (executed on hardware) may be expressed in a variety ofsoftware languages (e.g., computer code), including C, C++, Java®,Python, Ruby, Visual Basic®, and/or other object-oriented, procedural,or other programming language and development tools. Examples ofcomputer code include, but are not limited to, micro-code ormicro-instructions, machine instructions, such as produced by acompiler, code used to produce a web service, and files containinghigher-level instructions that are executed by a computer using aninterpreter. Additional examples of computer code include, but are notlimited to, control signals, encrypted code, and compressed code.

B. Communication Interface

The communication interface (930) may permit a operator to interact withand/or control the system (900) directly and/or remotely. For example, auser interface (934) of the system (900) may include an input device foran operator to input commands and an output device for an operatorand/or other users (e.g., technicians) to receive output (e.g., viewpatient data on a display device) related to operation of the system(900). In some variations, a network interface (932) may permit thecontrol system (920) to communicate with one or more of a network (970)(e.g., Internet), remote server (950), and database (940) as describedin more detail herein.

i. User Interface

User interface (934) may serve as a communication interface between auser (e.g., operator) and the control system (920). In some variations,the user interface (934) may comprise an input device and output device(e.g., touch screen and display) and be configured to receive input dataand output data from one or more sensors, input device, output device,network (970), database (940), and server (950). For example, sensorsignals generated by a sterile adapter sensor and surgical tool sensormay be processed by processor (924) and memory (926), and outputvisually by one or more output devices (e.g., optical waveguides).Sensor signals and/or attachment data may be received by user interface(934) and output visually, audibly, and/or through haptic feedbackthrough one or more output devices. As another example, operator controlof an input device (e.g., joystick, keyboard, touch screen) may bereceived by user interface (934) and then processed by processor (924)and memory (926) for user interface (934) to output a control signal toone or more of the robotic arm (910), tool driver (912), and surgicaltool (916). In some variations, the user interface (934) may function asboth an input and output device (e.g., a handheld controller configuredto generate a control signal while also providing haptic feedback to anoperator).

In some variations, the devices, systems, and methods comprise one ormore elements described in U.S. patent application Ser. No. 15/712,052,filed on Sep. 21, 2017, and titled “USER CONSOLE SYSTEM FOR ROBOTICSURGERY,” which is hereby incorporated by reference in its entirety.

1. Output Device

An output device of a user interface (934) may output sensor datacorresponding to a patient and/or system (900), and may comprise one ormore of an optical waveguide, display device, audio device, and hapticdevice. The display device may be configured to display a graphical userinterface (GUI). The user console (960) may include an integrateddisplay and/or video output that may be connected to output to one ormore generic displays, including remote displays accessible via theinternet or network. The video output or feed may also be encrypted toensure privacy and all or portions of the video output may be saved to aserver or electronic healthcare record system. A display device maypermit an operator to view procedure data, attachment data, system data,tool data, patient data, and/or other data processed by the controller(922). In some variations, an output device may comprise a displaydevice including at least one of a light emitting diode (LED), liquidcrystal display (LCD), electroluminescent display (ELD), plasma displaypanel (PDP), thin film transistor (TFT), organic light emitting diodes(OLED), electronic paper/e-ink display, laser display, and/orholographic display.

An audio device may audibly output patient data, tool data, attachmentdata, sensor data, system data, alarms and/or warnings. For example, theaudio device may output an audible warning when improper attachmentoccurs between the tool driver, sterile adapter, and surgical tool. Insome variations, an audio device may comprise at least one of a speaker,piezoelectric audio device, magnetostrictive speaker, and/or digitalspeaker. In some variations, an operator may communicate with otherusers using the audio device and a communication channel.

A haptic device may be incorporated into one or more of the input andoutput devices to provide additional sensory output (e.g., forcefeedback) to the operator. For example, a haptic device may generate atactile response (e.g., vibration) to confirm operator input to an inputdevice (e.g., joystick, keyboard, touch surface). In some variations,the haptic device may include a vibrational motor configured to providehaptic tactile feedback to a user. Haptic feedback may in somevariations confirm attachment and detachment of the sterile adapter orsurgical tool to the tool driver. Additionally or alternatively, hapticfeedback may notify that operation of the tool driver is inhibited fromdriving an output drive due to improper attachment and/or detachment inorder to prevent potential harm to the operator and/or system.

In some variations, the devices, systems, and methods comprise one ormore elements described in U.S. Patent Application Ser. No. 62/432,538,filed on Dec. 9, 2016, and titled “USER INTERFACE DEVICES FOR USE INROBOTIC SURGERY,” which is hereby incorporated by reference in itsentirety.

2. Input Device

Some variations of an input device may comprise at least one switchconfigured to generate a control signal. In some variations, the inputdevice may comprise a wired and/or wireless transmitter configured totransmit a control signal to a wired and/or wireless receiver of acontroller (922). For example, an input device may comprise a touchsurface for an operator to provide input (e.g., finger contact to thetouch surface) corresponding to a control signal. An input devicecomprising a touch surface may be configured to detect contact andmovement on the touch surface using any of a plurality of touchsensitivity technologies including capacitive, resistive, infrared,optical imaging, dispersive signal, acoustic pulse recognition, andsurface acoustic wave technologies. In variations of an input devicecomprising at least one switch, a switch may comprise, for example, atleast one of a button (e.g., hard key, soft key), touch surface,keyboard, analog stick (e.g., joystick), directional pad, pointingdevice (e.g., mouse), trackball, jog dial, step switch, rocker switch,pointer device (e.g., stylus), motion sensor, image sensor, andmicrophone. A motion sensor may receive operator movement data from anoptical sensor and classify an operator gesture as a control signal. Amicrophone may receive audio and recognize an operator voice as acontrol signal.

ii. Network Interface

As depicted in FIG. 9A, a control system (920) described herein maycommunicate with one or more networks (970) and computer systems (950)through a network interface (932). In some variations, the controlsystem (920) may be in communication with other devices via one or morewired and/or wireless networks. The network interface (932) mayfacilitate communication with other devices over one or more externalports (e.g., Universal Serial Bus (USB), multi-pin connector) configuredto couple directly to other devices or indirectly over a network (e.g.,the Internet, wireless LAN).

In some variations, the network interface (932) may comprise aradiofrequency receiver, transmitter, and/or optical (e.g., infrared)receiver and transmitter configured to communicate with one or moredevices and/or networks. The network interface (932) may communicate bywires and/or wirelessly with one or more of the sensors, user interface(934), network (970), database (940), and server (950).

In some variations, the network interface (930) may compriseradiofrequency (RF) circuitry (e.g., RF transceiver) including one ormore of a receiver, transmitter, and/or optical (e.g., infrared)receiver and transmitter configured to communicate with one or moredevices and/or networks. RF circuitry may receive and transmit RFsignals (e.g., electromagnetic signals). The RF circuitry convertselectrical signals to/from electromagnetic signals and communicates withcommunications networks and other communications devices via theelectromagnetic signals. The RF circuitry may include one or more of anantenna system, an RF transceiver, one or more amplifiers, a tuner, oneor more oscillators, a digital signal processor, a CODEC chipset, asubscriber identity module (SIM) card, memory, and the like. A wirelessnetwork may refer to any type of digital network that is not connectedby cables of any kind.

Examples of wireless communication in a wireless network include, butare not limited to cellular, radio, satellite, and microwavecommunication. The wireless communication may use any of a plurality ofcommunications standards, protocols and technologies, including but notlimited to Global System for Mobile Communications (GSM), Enhanced DataGSM Environment (EDGE), high-speed downlink packet access (HSDPA),wideband code division multiple access (W-CDMA), code division multipleaccess (CDMA), time division multiple access (TDMA), Bluetooth,near-field communication (NFC), radio-frequency identification (RFID),Wireless Fidelity (Wi-Fi) (e.g., IEEE 802.11a, IEEE 802.11b, IEEE802.11g, IEEE 802.11n), Voice over Internet Protocol (VoIP), Wi-MAX, aprotocol for email (e.g., Internet Message Access Protocol (IMAP), PostOffice Protocol (POP)), instant messaging (e.g., eXtensible Messagingand Presence Protocol (XMPP), Session Initiation Protocol for InstantMessaging, Presence Leveraging Extensions (SIMPLE), Instant Messagingand Presence Service (IMPS)), Short Message Service (SMS), or any othersuitable communication protocol. Some wireless network deploymentscombine networks from multiple cellular networks or use a mix ofcellular, Wi-Fi, and satellite communication.

In some variations, a wireless network may connect to a wired network inorder to interface with the Internet, other carrier voice and datanetworks, business networks, and personal networks. A wired network istypically carried over copper twisted pair, coaxial cable, and/or fiberoptic cables. There are many different types of wired networks includingwide area networks (WAN), metropolitan area networks (MAN), local areanetworks (LAN), Internet area networks (IAN), campus area networks(CAN), global area networks (GAN), like the Internet, and virtualprivate networks (VPN). As used herein, network refers to anycombination of wireless, wired, public, and private data networks thatare typically interconnected through the Internet, to provide a unifiednetworking and information access system.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the invention.However, it will be apparent to one skilled in the art that specificdetails are not required in order to practice the invention. Thus, theforegoing descriptions of specific variations of the invention arepresented for purposes of illustration and description. They are notintended to be exhaustive or to limit the invention to the precise formsdisclosed; obviously, many modifications and variations are possible inview of the above teachings. The variations were chosen and described inorder to best explain the principles of the invention and its practicalapplications, and they thereby enable others skilled in the art to bestutilize the invention and various implementations with variousmodifications as are suited to the particular use contemplated. It isintended that the following claims and their equivalents define thescope of the invention.

We claim:
 1. A system for use in a robotic surgical system, the systemcomprising: a tool driver configured to attach to a surgical tool via asterile adapter, the tool driver comprising at least one sterile adaptersensor configured to generate a first sensor signal corresponding to afirst attachment state between the tool driver and the sterile adapter,and at least one surgical tool sensor configured to generate a secondsensor signal corresponding to a second attachment state between thetool driver and the surgical tool, wherein the at least one sterileadapter sensor is operable to generate the first sensor signal in theabsence of a complete operative coupling between the tool driver and thesterile adapter; and a controller coupled to the tool driver, thecontroller comprising a processor and a memory, and the controllerconfigured to: receive at least one of the first and second sensorsignals from at least one of the sensors; generate attachment data usingat least one of the first and second sensor signals, the attachment datacomprising at least one attachment state between the tool driver, thesterile adapter, and the surgical tool; and control the tool driverusing the attachment data.
 2. The system of claim 1, wherein thecontroller is configured to actuate an output drive of the tool driverwhen the attachment state comprises partial attachment between thesterile adapter and the tool driver or the surgical tool and the sterileadapter.
 3. The system of claim 1, wherein the controller is configuredto actuate an output drive of the tool driver to actuate the surgicaltool when the attachment state comprises full attachment of the surgicaltool to the sterile adapter and the tool driver.
 4. The system of claim1, wherein the controller is configured to inhibit an output drive ofthe tool driver when the attachment state comprises one of detachmentand improper attachment between the tool driver, the sterile adapter,and the surgical tool.
 5. The system of claim 1, wherein the sterileadapter sensor comprises at least one of a proximity sensor, torquesensor, and rotary encoder, and the surgical tool sensor comprises aproximity sensor.
 6. The system of claim 1, wherein the controller isconfigured to output the attachment data to an operator.
 7. A method ofoperating a robotic surgical system, comprising: receiving at least onesensor signal generated by at least one of a sterile adapter sensorconfigured to generate a first sensor signal corresponding to a firstattachment state between a tool driver and a sterile adapter, and asurgical tool sensor configured to generate a second sensor signalcorresponding to a second attachment state between the tool driver and asurgical tool, wherein the at least one of the sterile adapter sensor isoperable to generate the first sensor signal in the absence of acomplete operative coupling between the tool driver and the sterileadapter; generating attachment data using at least one of the first andsecond sensor signals, the attachment data comprising at least oneattachment state between the tool driver, a sterile adapter, and asurgical tool; and controlling the tool driver using the attachmentdata.
 8. The method of claim 7, wherein controlling the tool drivercomprises one or more of actuating an output drive of the tool driverand notifying an operator of the attachment state.
 9. The method ofclaim 7, wherein controlling the tool driver comprises actuating anoutput drive of the tool driver when the attachment state comprisespartial attachment between the sterile adapter and the tool driver orthe surgical tool and the sterile adapter.
 10. The method of claim 7,wherein controlling the tool driver comprises actuating an output driveof the tool driver to actuate the surgical tool when the attachmentstate comprises full attachment of the surgical tool to the sterileadapter and the tool driver.
 11. The method of claim 7, whereincontrolling the tool driver comprises inhibiting an output drive of thetool driver when the attachment state comprises one of detachment andimproper attachment between the tool driver, the sterile adapter, andthe surgical tool.
 12. A robotic surgical system comprising: a tooldriver configured to attach to a surgical tool via a sterile adapter,wherein the tool driver comprises: a first housing comprising a firstoptical waveguide; an illumination source coupled to the first opticalwaveguide and configured to emit light, wherein the first opticalwaveguide is configured to propagate the light to the sterile adapter;and at least one rotatable output drive supported by the first housingand configured to communicate torque to the surgical tool through thesterile adapter, the sterile adapter comprises: a frame configured to beinterposed between the tool driver and the surgical tool, the framecomprising a second optical waveguide configured to receive the lightfrom the first optical waveguide and propagate the received light; aplate assembly coupled to the frame; and at least one rotatable couplersupported by the plate assembly and configured to communicate the torquefrom the output drive of the tool driver to the surgical tool, and thesurgical tool comprises: a second housing configured to couple to thesterile adapter, the second housing comprising a third optical waveguideconfigured to receive the light from the second optical waveguide; atleast one input drive supported by the second housing and configured toreceive the torque communicated from the output drive of the tool driverthrough the sterile adapter; and an end effector extending from thesecond housing and operatively coupled to the at least one input drive.13. The system of claim 12, wherein a characteristic of the lightcorresponds to an attachment state between at least two of the tooldriver, the sterile adapter, and the surgical tool.
 14. The system ofclaim 12, wherein the second optical waveguide is configured to receivethe light from the tool driver upon attachment of the sterile adapter tothe tool driver.
 15. The system of claim 12, wherein the third opticalwaveguide is configured to receive the light from the sterile adapterupon attachment of both the surgical tool to the sterile adapter and thesterile adapter to the tool driver.
 16. The system of claim 12, whereinthe first optical waveguide is disposed along an exterior surface of thefirst housing.
 17. The system of claim 12, wherein the second opticalwaveguide is disposed along an exterior surface of the frame.
 18. Thesystem of claim 12, wherein the third optical waveguide is disposedalong an exterior surface of the second housing.